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HOUSTON, TEXAS
AUGUST 29, 1975

DOCUMENT NO. D2- 118572

TITLE CREW APPLIANCE STUDY
FINAL REPORT

Contract NAS 9- 1 3905

August 29, 1975

Prepared for

National Aeronautics and Space Administration
Lyndon B. Johnson Space Center
Houston, Texas

Prepared by

B. W. Proctor
R. P. Reysa
D. J. Russell

Approved by

^2 . VC \W 'at

R. K. Nuno
Program Manager

BOEING AEROSPACE COMPANY
Houston, Texas

D2-I18572

REVISIONS

REV.

SYM

DESCRIPTION

DATE

APPROVED

•

HOU-3M-11 16 fLSBl ApjHovetf tl 67 AJT

P2-II8572

ABSTRACT

The crew appliance study was performed for NASA-JSC by the Boeing Aerospace
Company under Contract NAS 9-13965. A detailed study of crew appliances
was initiated because they generally require large amounts of electrical
power, have high heating or cooling requirements, and are users of liquid/
gas consumables. These crew appliance interface requirements can signifi-
cantly impact the design of a manned space vehicle environmental control
and life support system (ECLSS). This study identified, by means of a
thorough literature search, viable crew appliance concepts. Trade studies
were performed of these concepts for food management, personal hygiene,
housekeeping, and off-duty habitability functions to determine which best
satisfy the Space Shuttle Orbiter and Modular Space Station mission require-
ments. In conjunction with these studies, models of selected appliance
concepts not currently included in the G-189A Computer Program subroutine
library were developed and validated. Development plans of selected
appliance concepts were generated for future NASA-JSC reference. As an
extension to the basic contract, a Shuttle freezer conceptual design was
developed and a test support activity was provided for regenerative
environmental control life support subsystems.

KEY WORDS

Clothes Washer
Crew Appliances
Dishwasher
Food Management
Modular Space Station
Off-Duty Activities
Personal Hygiene

Refuse Management
Shower

Shuttle Orbiter

Spacecraft Environmental Control
Waste Collection
Refrigerator/Freezer

D2-IIC572

TABLE OF CONTENTS

V. ✓ r

SECTION PAGE

REVISIONS i

ABSTRACT AND KEY WORDS ii

TABLE OF CONTENTS ii i

LIST OF FIGURES V

LIST OF TABLES vii

REFERENCES vlii

1.0 Crew Appliance Study Summary 1-1

1.1 Task 1.0 Concept Study 1-2

1.2 Task 2.0 Preparation of Math Models 1-4

1.3 Development Plans 1-6

1.4 Test Support 1-7

1.5 Shuttle Freezer Conceptual Design 1-8

1.6 Delivered Items 1-10

2.0 Crew Appliance Study . . . 2-1

2.1 Task 1.0 Concept Study 2-6

2.1.1 Source Documentation 2-6

2.1.2 Concept Study Results 2-11

2. 1.2.1 Mission Baseline Description 2-11

2. 1.2.2 Appliance System Description 2-16

2. 1.2. 3 Appliance Concept Function Matrix. . . . 2-17

2.1.3 Description of Selected Appliances 2-24

2. 1.3.1 Vehicle Crew Appliance Requirements. . . 2-24

2. 1.3. 2 Weighted Trade Study 2-26

2. 1.3.3 Crew Appliance System Optimization . . . 2-28

2. 1.3.4 Selected Shuttle Appliance Concepts, . . 2-29

2. 1.3. 5 Selected Space Station Appliance

Concepts 2-39

2.1.4 Shuttle Freezer Conceptual Design 2-45

2. 1.4.1 Freezer Volume Optimization 2-46

2. 1.4. 2 Freezer Envelope Definition 2-46

2. 1.4.3 Freezer Refrigeration System

Description 2-47

2. 1.4.4 Refrigeration System Trade Study .... 2-50

2. 1.4. 5 Refrigeration Unit Design. ....... 2-54

2. 1.4.6 Mechanical Design and Structural

Analysis 2-54

2. 1.4. 7 Freezer Thermal Analysis and

Evaluation 2-56

2.2 Task 2.0 Preparation of Math Models 2-64

( 2.2.1 Computer Routine Development 2-66

i ii

D2-1I £572

TABLE OF CONTENTS (Concluded)

SECTION PAGE

2. 2. 1.1 CHILLR Subroutine Description 2-69

2.2. 1.2 FTRAY Subroutine Description ...... 2-72

2. 2. 1.3 RQSMOS Subroutine Description 2-72

2. 2. 1.4 SHOWER Subroutine Description 2-75

2. 2. 1.5 WASDRY Subroutine Description 2-77

2. 2. 1.6 WASTEC Subroutine Description 2-78

2.2.2 Validation of Routines . 2-82

2. 2. 2.1 Individual Appliance Subroutine

Checkout . 2-82

2. 2. 2. 2 Shuttle Orbiter Appliances Simulation. . 2-82

2. 2.2.3 Space Station Appliances Simulation. . . 2-83

2.3 Task 3.0 Generation of Development Plans 2-95

2.3.1 Shuttle "Kit" Freezer Development ........ 2-95

2.3.2 Washer/Dryer Combination (Dishes and

Clothes) Development 2-98

2.3.3 Shower Development. 2-102

3.0 Results, Conclusions, and Recommendations ..... 3-1

si v

D2-IIE57

LIST OF FIGURES

FIGURE ‘ PAGE

1.5-1 Shuttle Freezer Conceptual Design Features 1-9

2.0- 1 Crew Appliance System Organization. 2-3

2.1**1 Crew Appliance Subject Filing Index 2-7

2.1- 2 Examples of the Crew Appliance Bibliography Sections 2-10

2.1- 3 Shuttle Baseline Mission 2-12

2.1“4 Space Station Baseline Mission 2-13

2.1- 5 Shuttle Orbiter Timeline 2-14

2.1- 6 Space Station Timeline 2-15

2.1- 7 Crew Habitability and Appliance Functions and Concepts. . . . 2-18

2.1- 8 Example - Appliance Concept Function Matrix 2-23

2.1- 9 Crew Compartment Configuration 2-48

2.1- 10 Storage to R/U Heat Transmission Options 2-49

2.1- 11 Effect of Coolant Tubing Spacing on Food Temperature 2-58

2.1- 12 Transient Freezer Thermal Response Under “Worst-Case"

Conditions 2-59

2.1- 13 Transient Medical Sample Temperature and Coolant Heat

Removal under "Worst-Case" Conditions .... 2-60

2.1- 14 Transient Freezer Thermal Response With No Door Opening

or Medical Sample Insertion ... 2-62

2.1- 15 Freezer Transient Coolant Heat Removal With No Door

Openings or Medical Sample Insertion . 2-63

2.2- 1 CHILLR Component and Flow Schematic 2-70

2.2- 2 Thermal Model of Refrigerator/ Freezer Locker (a)

and Chiller (b) and (c) 2-71

2.2- 3 Typical Skylab-type Food Warming/Serving Tray 2-72

2.2- 4 Thermal Model of a Single Food Warming Cavity 2-73

2.2- 5 ROSMOS Component Flow Schematic . ^ 2-74

2.2- 6 Shower Model Flow Schematic 2-76

2.2- 7 Thermal Model of Shower Stall Component ... . . 2-77

2.2- 8 WASDRY Component Flow Schematic 2-79

2.2- 9 Thermal Model for WASDRY Component 2-79

2.2- 10 WASTEC Component Flow Schematic 2-80

2.2- 11 Thermal Model for WASTEC Component 2-81

P2-II8572

LIST OF FIGURES (Concluded)

FIGURE ‘ PAGE

2.2- 12 Flow Schematic of G-189A Appliance Components Added to

Basic Shuttle Orbiter Model , 2-84

2.2- 13 G-189A Flow Schematic of Space Station Cabin Gas Loop .... 2-87

2.2rl4 G-189A Flow Schematic of Space Station Water Loop 2-88

2.2- 15 Other G-189A Components Used in Space Station Model 2-89

2.2- 16 Appliance Usage Schedules in Space Station Transient

Simulation 2-90

2.2- 17 G-189A Flow Schematic of Space Station Shower Model ..... 2-91

2.2- 18 G-189A Flow Schematic of Space Station Clothes

Washer/Dryer Model 2-92

2.2- 19 G-189A Flow Schematic of Space Station Dishwasher/

Dryer Model 2-93

2.2- 20 G-189A Flow Schematic of Space Station Dryjohn Model 2-94

2.3- 1 Freezer Development Schedule 2-99

2.3- 2 Washer/Dryer Development Schedule 2-103.

2.3- 3 Shower Development Schedule 2-104

D2-II8572

LIST OF TABLES

TABLE * PAGE

1.1- 1 Summary of Shuttle Crew Appliance Concept Selection 1-2.1

1.1- 2 Summary of Space Station Crew Appliance Concept

Selection 1-2.2

1.6-1 Delivered Items March 7, 1974 to August 29, 1975 1-11

2.1- 1 Shuttle Appliance System Requirements 2-25

2.1- 2 Space Station Appliance System Requirements 2-27

£.1-3 Shuttle Appliance Concept Summary Function Matrix 2-30

2.1- 4 Space Station Appliance Concept Function Matrix Summary. . . 2-32

2.1- 5 Refrigeration Unit Candidates 2-51

2.1- 6 Crew Appliance Selection Matrix for Freezer 2-53

2.1- 7 Refrigeration Unit Performance . . . 2-55

2.2- 1 Appliance Component Options Assumed in

Shuttle Qrbiter Simulation 2-85

2.3- 1 Appliance Development Plans Summary 2-96

vii

D2-I18572

REFERENCES

1. B. W. Proctor, R. P. Reysa, D. J. Russell, "Crew Appliance Concepts,"
Boeing Document D2-1I8561, July 25, 1975.

2. D. J, Russell, "Crew Appliance Computer Program Manual," Boeing
Document No. D2-118571, August 29, 1975.

3. B. W. Proctor, D. J. Russell, "Shuttle Freezer Conceptual Design,"
Boeing Document No. D2-118569, August 22, 1975.

4. "Modular Space Station Detailed Preliminary Design Volume 1,”

Sections 1 through 4.4, McDonnell Douglas Document No. MDAC-G2582,
November 1971.

5. "G-189A Generalized Environmental -Thermal Control and Life Support
Systems Computer Program," McDonnell Douglas Document No. MDAC-G2444,
September 1971.

6. "Space Shuttle System Baseline Reference Mission Volume 2,'- Revised
Mission 2," NASA- JSC Document No. MSC 07896, August 17, 1973.

7. "Space Shuttle Systems Baseline Reference Mission Volume 2," NASA-JSC
Document No. MSC 07896, December 11, 1972,

8. "Preliminary Space Station Design Requirements for Environmental
Thermal Control and Life Support System Equipment," NASA-JSC Document
No. MSC 01484.

9. "Shuttle Orbiter Passenger Compartment Habitability Requirements
Study for Flight Personnel Accommodations," NASA-JSC Internal Note
71-EW-8, MSC 04425, May 1971.

10. "Laundering In Space— A Summary of Recent Developments," ASME
Paper No. 73-ENAS-43, July 19, 1973.

11. "Space Station Prototype Environmental /Thermal Control and Life
Support System; Preliminary Design Package," Hamilton Standard
Document No. 18, 19 and 20.

12. "Shuttle Kit Freezer Refrigeration Unit Conceptual Design," LTV
Document No. T122-RP-044, August 22, 1975.

* * •

D2-II8572

1.0 CREW APPLIANCE STUDY SUMMARY

This report documents the results of the Crew Appliance Study conducted
under Contract NAS 9-13965. Three main tasks were considered during the
study:

(1) Task L0 - Concept Study

(2) Task 2.0 - Preparation of Mathematical Models

(3) Task 3.0 - Generation of Development Plans

The concept study task, documented in Crew Appliance Concepts Report
(Reference 1), provided a literature search to identify space-oriented
crew appliance concepts; collected, categorized, and documented the
available vehicle oriented appliance data; and developed an optimized
appliance system for both the Shuttle and Space Station vehicle missions.
Mathematical modeling of the selected appliance concepts and verification
of the resulting math models were accomplished during the preparation of
mathematical models task. Results of this are reported in the Crew
Appliance Computer Program Manual (Reference 2). The generation of develop-
ment plans task identified future appliance concept development activities.
In addition to this basic study effort, a Regenerative Environmental Con-
trol Life Support oubsystem hardware test support activity and a Shuttle
freezer conceptual design were accomplished and developed as an extension
to the basic Crew Appliance contract. The freezer design study effort is
described in the Shuttle Freezer Conceptual Design report (Reference 3).

1-1

D2-I18572

l.X TASK 1.0 - CONCEPT STUDY

The literature search produced an abstract file pertaining to 299 appliance-
related documents which were file coded according to subject content. A
brief description of each document's contents and its worthiness to the
appliance study were included. These documents and 382 others reviewed
during the study were compiled to form an appliance subject bibliography.
Contained in Appendix A of the Crew Appliance Concepts Report, the bibliog-
raphy has been placed in a computerized format which can be accessed
remotely on a time-sharing computer.

Appliance concepts introduced in the literature search and found to be
technically reasonable were included in the list of concepts to be reviewed

for inclusion in the appliance system. A total of 135 concepts were identi-

■

tied and categorized. All the available engineering parameters relating
to the 135 concepts were compiled and summarized in an Appliance Cpncept
Function Matrix. These matrices were constructed for both the Shuttle and
Space Station mission operations with the basic appliance functional
parameters being adjusted to reflect the mission requirements.

Various appliance concepts in each habitability function category were
traded to determine which concept best satisfied the mission requirements
for a particular function. Factors such as weight, volume, electrical power
and thermal requirements, reliability, safety, and cost were weighed. The
quality of the trade task was enhanced by the use of a Boeing- developed
computerized trade routine which easily allowed a variation of weighting
factors to be repeatedly assigned and assessed. Concepts which were found
in the trade task to best satisfy the Shuttle and Space Station mission
requirements are tabulated in Table 1.1-1 and Table 1.1-2, respectively.

Appliance concepts identified in the trade program formed the basic optimum
appliance system. This system was further optimized by alternating concepts
until the conceptual system was within the vehicle requirements or until
each requirement deficiency was reduced to a minimum. Final selected con-
cepts for each habitability function in the Shuttle and Space Station
appliance systems are tabulated in Table 1.1-1 and Table 1.1-2, respectively.

1-2

D2-NS572

' TABLE 1.1-1

SUMMARY OF SHUTTLE CREW APPLIANCE CONCEPT SELECTION

FIRST

SECOND

HA3ITABILITY

H' SUABILITY

APPLIANCE

CONCEPT

RATED

SUBSYSTEM

FUNCTION

CHOSEN

CONCEPT

FOOD STORAGE

REFRIGERATED

Space Radiator

Thermoelectric

FOOD

HARMING

Heating Trays

Convective Oven

FOOD

PREPARATION

rWuttjtnCfi 1

DISH CLEANUP

Reusable Dishes

GALLEY

CLEANUP

and Utensils
with Disposable

and Disposable
Utensils with

Viet/ Dry Wipes

Wet/Dry Wipes

Disposable
Wet/Dry Wipes

•

FECAL

COLLECTION

Dry John System

Apollo System

Skylab System

HASTE

URINE

Apollo System

Sky lab System

COLLECTION

VOMITUS

COLLECTION

Disposable Bags

Intimate Adaptot

PERSONAL

PARTIAL BODY

Disposable Wet

Skyl ab-Type

HYGIENE

BODY

CLEANSING

HASHING

Wipe

Disposable

Washcloth

PARTIAL BODY
DRYING

Disposable Dry

Electric Dryer

SHAVING

Safety or

Safety or .

Safety or

PERSONAL

Windup

GROOMING

DENTAL CARE

Toothbi ush

Toothbrush

Electric

w/Dentifrice

v;/Dentifrice

Toothbrush

EQUIPMENT

SURFACE

Disposable Wet/

Sky 1 ab-Type

CLEANUP

WIPING

Dry Wipes

Disposable Clotf

MANUAL

Disposable Trash

Disposable

COLLECTION

Bag

Recepticles

HOUSEKEEPING

REFUSE

VACUUM .•

Skylab-Typa

Vacuum-Vented

Skylab-Type

MANAGEMENT

COLLECTION

Electric

REFUSE

Storage Bin/

Vacuum Storage

DISPOSAL

Container

GARMENT/LINEN

CLOTHES WASH/

Disposable

Mechanical

MAINTENANCE

DR s'

Clothes

w/Clothes Line

MUSIC

Cassette Record
Recorder

ENTERTAINMENT

LIBRARY

Books

■fc

OFF-DUTY

TELEVISION

Cc^-ercial Type

ACTIVITIES

GAMES

Cards, Handball,

Etc.

PHYSICAL

EXERCISERS

Exer Gym, Hand

CONDITIONING

Exerciser

* NOT TRADED

PAGB'ia •
" POOR QUAIOT

1 - 2.1

D2-IIE572

TABLE 1.1-2

SUMMARY OF SPACE STATION CREW APPLIANCE CONCEPT SELECTION

HABITABILITY

SUBSYSTEM

HABITABILITY

FUNCTION

APPLIANCE
FUNCTION '

CONCEPT

CHOSEN

FIRST

RATED

CONCEPT

SECOND

RATED

CONCEPT

FOOD ..
STORAGE

REFRIGERATED

FROZEN

Space Radiator
Space Radiator

Thermoelectric

FOOD

MANAGEMENT

FOOD

PREPARATION

HARMING

Heating Trays

Convective Oven

GALLEY

CLEANUP

DISH CLEANUP

Water Spray
Wash/Elec.
Heat Dry

Reusable Dishes
and Disposable
Wet/Dry Wipes

Reusable Cups £
Dishes -
Disposable
Utensils and
Disposable Wet/
Dry Wipes

HASTE

COLLECTION

FECAL

COLLECTION

URINE ■
COLLECTION

Dry John System

Apollo System
Apollo System

Sky lab System
Skylab System

VOHITUS

COLLECTION

Disposable Bags

Intimate

Adaptor

SHOWER

Collapsible

Mechanical

•

PERSONAL

HYGIEht

BODY

CLEANSING

PARTIAL BODY
WASHING

PARTIAL BODY
DRYING

Reusable Wipes
Reusable Wipes

Skylab-Type

Disposable

Washcloths

Disposable
Dry Wipes

, *

SHAVING

Windup

Vacuum Driven

• - *

PERSONAL

GROOMING

HAIRCUTTING
NAIL CARE

Razor Comb

Vacuum

Collection

Manual Clipper

Razor Comb

Vacuum

Collection

Manual Clipper

Povjer Clipper
Vacuum
Collect! on

Nail File

Vacuum

Collection

► •

DENTAL CARE

Toothbrush
w/Denti fri ce

El ectri c
Toothbrush

EQUIPMENT

CLEANUP

SURFACE

WIPING

Reusable Wet/
Dry Wipes

Disposable Wet/
Dry Wipes

Sponge

Skylab-Type

MANUAL •’
COLLECTION

Disposable Bags

Disposable

Recepticles

HOUSEKEEPING .

REFUSE

MANAGEMENT

VACUUM

COLLECTION

REFUSE

PROCESSING *

Sky lab- Type

(Electric)

Compactor
(Air Pressure)

Skylab-Type

(Electric)

Compactor
(Air Pressure)

Vacuum Vented

Compactor

(Vacuum)

REFUSE

DISPOSAL

Storage Bin/
Container

Vacuum Storage

GARMENT/LI MEN
MAINTENANCE

CLOTHES
WASH/ DRY

Water Spray
Agitation Plus
Electric Dry

Disposable

Clothes

Water Spray
Agitation Plus
Clothes Line

MUSIC

Casotte Recorder

OFF-DUTY

ACTIVITIES

ENTERTAINMENT

LIBRARY

TELEVISION

GAMES

Books

Commercial Type

Cards, Handball;
Etc.

* ,
*

PHYSICAL

CCNOITIONING

EXERCISERS

Exer Gym,

Hand Exerciser

. * ' wgt TRAfirii _ a h „

D2-1I8572

1.1 (Continued)

Requirements for the Shuttle Appliance System were sufficiently defined;
and the optimized system developed in this study is well within these
defined thermal, electrical, weight and volume requirements. The maximum
instantaneous heat rejection load of the optimum system to the Shuttle
ECLSS is 464 watts (1583 Btu/hr) less than the specified requirements.

Appliance requirements described in the NASA Modular Space Station Study
(Reference 4) were used for comparison with the optimized Space Station
characteristics. Because of insufficient definition of heat rejection and
electrical power data in some areas, it was possible only to totally compare
weight and volume. The optimized system was selected to provide a balanced
system whereby heat rejection and electrical penalties were paid, where
necessary, to eliminate high weight and volume-type appliance concepts.

The resulting optimized Space Station appliance system is within the
weight and volume system requirements (Modular Space Station Study).

Maximum instantaneous heat rejection load of the conceptual system to the
ECLSS is 1501 watts (5122 Btu/hr) directly to the coolant and 2716 watts
(9268 Btu/hr) as heat leakage to the cabin.

1-3

D2-1IE572

1.2 TASK 2.0 - PREPARATION OF MATH MODELS

Computer subroutines were developed to model the thermodynamic behavior
of the selected appliance concepts within the G-189A ETCLS system simu-
lation computer program (Reference 5). The optimum appliance concepts
selected from the trade studies discussed in Paragraph 1.1 are shown in
Tables 1.1-1 and 1.1-2 for Shuttle Orbiter and Modular Space Station.
Some of these concepts did not require a new G-189A subroutine since
(1) a routine is already available, (2) no thermal/mass exchange is in-
volved, or (3) operation of the component is so simple it requires only

a minor addition to the G-189A (GPOLY)
category are as follows:

o Reusable dishes, wet
and dry wipes

o Vomitus collection

o Partial body washing,
wet wipes

o Partial body drying, dry
wipes or electric dryer

6 Wet shave

o Windup razor

o Toothbrush

o Vacuum refuse collection

o Tape recorder, TV

routine logic. Appliances in this

None needed
None needed

Simple GPOLY logic only
required

None needed (or a simple
heater using G-189A routine
ALTCOM)

GPOLY logic required for
water usage, only

None needed (or a simple heater
using G-189A routine ALTCOM if
electric)

GPOLY logic required for water
usage only

GPOLY logic only required, or
G-189A routine ALTCOM for an
electric heater

For the remaining appliances, si* new G-189A subroutines have been written,
some of which will model more than one type of appliance.. These subroutines
are generally described as follows:

1.2 (Continued)

D2-118572

Subroutine

Name Description

CWILLR (simulates a thermally insulated locker cooled either

by an externally chilled fluid or a self-contained
refrigeration unit)

* Freezer

* Refrigerator

FT RAY

* Food warming/serving tray (Sky! ab- type)

ROSMOS

* Reverse osmosis waste water treatment unit

SHOWER

. * Spacecraft whole body shower

WASDRY

* Clothes washer

* Clothes dryer

* Combined clothes washer/ dryer

* Dishwasher/dryer

* Towel /cloth drying rack

WASTEC

* Dryjohn

* Urinal

These subroutines allow analysis of future spacecraft ECLS systems
involving crew appliances using the G-189A program. Subroutines have been
written in generalized terms to allow easy accommodation for changing
appliance designs. Their performance predictions have been correlated
with test data where available, and excellent agreement has been obtained.
Where test data were not available, the results were compared with inde-
pendent analysis and found to be reasonable and accurate. The new sub-
routines have been used to model the selected optimum appliances in all-up
G-189A simulations of the Shuttle Orbiter and Modular Space Station ECLSS.
The results from these runs demonstrate their operational status within
the G-.189A computer program.

D2-HC57T

1.3 DEVELOPMENT PLANS

Concurrent with the crew appliance study activity, possible areas of
development were noted for the selected appliance concepts. The majority
of the appliances are state-of-the-art due to the nature of the optimization
techniques used in the trade program. Generally those appliances identified
as requiring development were the ones chosen fur Space Station to maximize
the thermodynamic, electrical power, and consumables requirements. The
partial body washing and fecal/urine collection appliances would have
required a development plan; however, NASA-JSC has initiated study efforts
to develop these concepts.

Appliances identified as requiring further development were the food
storage refrigerator/freezer, the garment/! inen maintenance clothes washer/
dryer, whole body shower, and dish cleanup dishwasher. In most cases, a
preprototype unit of each of these appliances has already been initiated by
NASA-JSC and therefore the development plans generated are an adjunct to
these efforts to -improve the performance of these appliances. The develop-
ment plans generated provide a recommended technical approach which is
accompanied with a development schedule. These plans are a result of the
literature survey conducted during the study, consultation with NASA-JSC
technical monitors, and the whole body shower test support activity experience.

1-6

D2-118572

1.4 TEST SUPPORT

The test support phase as an extension to the Crew Appliance contract has
provided assistance to NASA- JSC during the buildup of an Advanced
Regenerative Environmental Control Life Support System (RECLSS) laboratory
for testing RECLSS subsystems. This test support activity has included
technical assistance during laboratory buildup, definition of RECLSS
subsystem testing and real time test support. The laboratory buildup has
progressed to support seven RECLSS subsystems during the contract period.
The definition of RECLSS subsystem testing has included the generation of
RECLSS test requirements, plans, and preparation sheets for four of the
seven subsystems. Direct test support activities, thus far, have included
functional and verification testing of the Oxygen Generation Subsystem
and functional testing of the Vapor Compression Distillation and Humidity
Co'ntrol Subsystems.

The Oxygen Generation Subsystem was successfully run for a total of 100
hours. The continuous verification test was interrupted by a manually
initiated shutdown occurring 66 hours into the test. The shutdown was
dictated by loss of water flow to the electrolysis module. Subsequent
data analysis confirmed the shutdown was caused by a blockage of the water
flow orifice. The subsystem was restarted and completed the remaining
34 hours of continuous testing without further incidents. All parameters
operated within designed specification limits. The subsystem required
numerous modifications prior to this successful long-term, 100-hour verifi-
cation tests; the most notable modification being the addition of a pump
head bleed system. The bleed system allowed the subsystem to operate
without short-term vapor-locking of the fluid pump. A more detailed
discussion of the subsystem modifications and test data analysis is con-
tained in the Quick Look Test Report released by MASA-JSC.

1-7

D2-I18572

1.5 SHUTTLE FREEZER CONCEPTUAL DESIGN

As an extension to the Cm/ Appliance contract, a study was conducted to
develop a conceptual "kit 11 freezer to be used to store food and medical
samples on long duration Shuttle missions. The design developed is a
portable unit weighing 70 pounds which can be transported fully assembled
through Orbiter side hatch and mounted in the crew compartment on the
storage module support system. A storage volume of 4.6 cubic feet with
a capacity of 215 pounds of packaged food or 128 pounds of medical samples
can be maintained at an average temperature of -10°F. Refrigeration is
provided by an air-cooled unit utilizing a Stirling cycle principle to
develop 75 watts of cooling with a peak electrical power requirement of
211 watts. A description of the freezer design is given in Reference 3.

Results of thermal analyses conducted to evaluate the steady state and
transient storage volume temperature distributions and critical stored item
and component temperatures are presented. Data are also given v/hich describe
the effects of coolant tubing spacing on wall temperature distribution.

Drawings were prepared to provide a detailed illustration of the mechanical
and structural concepts employed in the freezer design and to validate
packaging schemes and dimensional tolerances. Stress analyses of critical
structural areas were made to insure freezer structural integrity could be
maintained during all phases of the Shuttle mission.

The primary elements of the Shuttle conceptual freezer developed in this
study are illustrated in the drawing shown in Figure 1.5-1.

1-8

MOUNTING

POST

OUTER

BOX

OUTER

DOOR

R/U PALLET

COOLING

COIL

INNER

DOOR

Figure 1.5-1. Shuttle Freezer Conceptual Design Features

D2-US572

D2-I1S572

1.6 DELIVERED ITEMS

Deliveries made during the contract are summarized in Table 1,6-1. The
overall program schedule and major event milestones met are illustrated
on page 1-14.

D2-1IS572

TABLE 1.6-1

DELIVERED

ITEMS MARCH 7,

1974 TO AUGUST 29,

1975

TITLE

DRL LINE
ITEM No.

DRD No.

DATE

DELIVERED

Report, Crew
Appliance Study
Plan

—

March 27, 1974

Progress Report
No. 1, Crew
Appliance Study

MA-010TA

April 8, 1974

Progress Report
No. 2, Crew
Appliance Study

MA-010TA

May 8, 1974

Progress Report
No. 3, Crew
Appliance Study '

MA-010TA

June 7, 1974

Progress Report
No. 4, Crew
Appliance Study

MA-010TA

July 8, 1974

Progress Report
No. 5, Crew
Appliance Study

MA-010TA

August 9, 1974

Bibliography-Crew
Appliance Study

September 9, 1974

Progress Report
No. 6, Crew
Appliance Study

MA-010TA

September 9, 1974

Progress Report
No. 7, Crew
Appliance Study

MA-010TA

October 7, 1974

Progress Report
No. 8, Crew
Appliance Study

MA-OIOTA

November 8, 1974

Shuttle Orbiter Freezer
Kit Preliminary Thermal
Design Requirements

November 15, 1974

*Delivered in accordance with Program Schedule

D2-1SE572

TABLE 1.6-1 (Continued)

DELIVERED

ITEMS MARCH 7,

1974 TO AUGUST 29,

1975

TITLE

DRL LINE
ITEM No.

DRD No.

DATE

DELIVERED

Progress Report
No. 9, Crew
Appliance Study

MA-010TA

December 9, 1974

Preliminary Concept
Study Report

SE-542T

December 20, 1974

Progress Report
No. 10, Crew
Appliance Study

MA-010TA

January 6, 1975

Progress Report
No. 11, Crew
Appliance Study

MA-010TA

February 10, 1975

Study Plan
Addendum

February 10, 1975

Progress Report
No. 12, Crew
Appliance Study

MA-Q10TA

March 10, 1975

Trip Report-Oxygen
Generation Subsystem
Electrolysis Module
Failure Analysis
at G.E.

March 14, 1975

CO 2 Collection/
Humidity Control
Subsystem Test Plan

**•

“

March 18, 1975

Shuttle Freezer Study-
Mid-term Briefing
Document

March 21, 1975

Progress Report
No. 13, Crew
Appliance Study

MA-010TA

April 7, 1975

Interim Crew Appliance
Computer Program
Manual

•k

*-•

April 28, 1975

*Delivered in accordance with Program Schedule

1-12

. 432-118572

TABLE 1.6-1 (Concluded)

DELIVERED ITEMS MARCH 7,

1974 TO AUGUST 29,

1975

TITLE

DRL LINE
ITEM No.

DRD No.

DATE

DELIVERED

Progress Report
No. 14, Crew
Appliance Study

MA-010TA

May 7, 1975

Progress Report
No. 15, Crew
Appliance Study

MA-010TA

June 9, 1975

Shuttle Freezer
Study - Conceptual
Design Review

June 27, 1975

Progress Report
No. 16, Crew
Appliance Study

MA-010TA

July 7, 1975

Progress Report
No. 17, Crew
Appliance Study

MA-010TA

August 21, 1975

Shuttle Freezer
Conceptual Design

August 22, 1975

Crew Appliance
Computer Program
Manual

DM-166T

August 29, 1975

1-13

•COMPUTE* ROUT If.E DEVELOPMENT
o Freezer Kit Model
o Medal Updates Resulting
from Test Data
•VALIDATION OF ROUTINES
o Freezer Kit Model
o M odel Updates
>'K 3 G c Of bEVELOPMSfi

oCAEVrl'PtlANCES
•FREEZE?. .

•REPORTS

PROG c AM PLAN
o Study Plan Addendum

: CRE.I ALLIANCE CONCEPT
SIELIClGRAPBY
INTERIM USER'S MANUAL
■ COMPUTER PP.CSRfM AND
USER'S MANUAL
FINAL REPORT

3/10

TEST PL API S/ f? EQU I REMEN TS
i MONTHLY PROGRESS
•REVIEWS AMD DEMONSTRATION

•-AS REQUIRED

A A A A A

A A A

U I

4 t

Program Schedule

VKTT,

D2-I1S572

2.0 CREW APPLIANCE STUDY

The crew appliance study was funded under Contract NAS 9-13965 by the Crew
Systems Division of NASA JSC to develop conceptual crew appliance systems
which will satisfy the mission requirements for the Shuttle Orbiter and
the Modular Space Station.

Major crew appliances generally require large amounts of electrical energy;
have high heating or cooling requirements; and are users of liquid/gas
consumables. These crew appliance interface requirements can significantly
impact the design of a manned space vehicle environmental control and life
support system (ECLSS). The objective of this study is to analyze crew
appliances to minimize the thermodynamic, power, weight, volume, and utili-
ties support required for the ECLSS using an optimization technique to
derive the most efficient mix of appliances. Crew appliance costs were
heavily factored in favor of the state-of-the-art concepts; however, all
appliance concepts considered during the study were of a sound design.

Three main tasks of the study which were divided into the six phases are
described briefly in this section. The six phases are:

(1) Compilation and organization of source documentation \

(Paragraph 2.1.1 - source documents) I

(2) Appliance concept description development (Paragraph 2.1,2, |

Concept Study) j

(3) Selection of optimum appliance concepts (Paragraph 2.1.2, /

Description of Selected Appliances)

(4) Development of math models of selected crew appliances |

(Paragraph 2.2.1, Math Model Descriptions) l

(5) Validation of developed math models (Paragraph 2.2.2, j
Math Model Validation)

(6) Generation of appliance development plans (Paragraph 2.3.1,
Future Development Plans)

In addition to the above tasks, an extension was made to the contract to
^ develop a conceptual design of a freezer.

2-1

Task 3.0 'Task 2.0 Task 1.0

-1 J . ... l I t t i

D2-IIE572

2.0 (Continued)

In order to thoroughly achieve the objectives of the study, all of the
available appliance- related reference data were compiled from various
library and contractor sources during Phase 1 . A review of these references
produced a list of documents which were considered most applicable to the
appliance functions. 'These references were categorized and indexed and
an abstract of. each document written on an index card. The compendium of
these index cards has been delivered to NASA JSC and is on file with
J. R. Jaax, Building 7.‘

A bibliography of all document titles which are pertinent to the crew
appliance study was compiled and published as Appendix A to the Crew Appliance
Concepts document (Reference 1). The bibliography was ordered by three
methods: (1) consecutive reference number, (2) alphabetically, and (3)

index codes and computerized to catalog the large number of references and
to provide easy retrieval of information. A description of the procedures
used to retrieve information from the bibliography using a remote computer
terminal was also documented in the Crew Appliance Concepts report. The
source documentation effort is described in Section 2.1.1.

Data derived from', the. referenced documents provided a basis for the Phase 2
appliance concept descriptions development. The Crew Appliance System was
organized into Habitability Subsystem, Habitability Function, and Appliance
Function; and the most feasible concepts were identified for each function, ...
This organization is shown schematically in Figure 2,0-1. Engineering data
derived for each appliance were normalized to the established Shuttle Orbiter
and Modular Space Station reference missions. These data were entered
into an Appliance Concept Function Matrix to provide direct comparisons of
concepts which serve a particular appliance function.

Concepts contained within each Appliance Function were traded using a param-
eter weighted technique designed to reflect the Shuttle Orbiter and Space
Station vehicle appliance requirements. A computer program was developed
and used to perform the trade studies. In addition to the concept

2-2

r >

> . s, y

•f

Figure 2.0-1. Crew Appliance System Organization

D2-I1E57

D2-II8572

2.0 (Continued)

operational requirements considered, cost, reliability, maintainability,
and safety were also factored into the trade program. The advantages of
a computerized trade study are rapid turnaround time for parameter changes,
changes in weighting distribution, and mission resupply time. The detailed
engineering data utilized for the trade studies, the Appliance Concept
Function Matrix, and the trade study program results are presented in
Appendices B and C of the Crew Appliance Concepts document. The concept
study results are described in Section 2.1.2.

During Phase 3, appliance concepts with the highest rating (results of
Phase 2) in each of the appliance functions were optimized on a subsystem
and a system level. The appliance system optimization study identified
appliance function deficiencies by a comparison of the top rated concept
requirements to the vehicle requirements derived from source documentation
and by including crew time, crew performance, and usage time considerations.

The trade program and optimization technique used for this study not only
provide the. optimized appliance systems for the Shuttle Orbiter and Modular
Space Station, but can be used with some manipulation for other vehicle
programs. In addition, direct comparisons of appliance systems other than
the ones chosen by the study can be readily made utilizing the data pre-
sented within these documents. The description of selected appliances is
presented in Section 2.1,3.

The Phase 4 appliance concept math modeling task was performed to develop
computer subroutines to simulate the selected optimum appliances thermodynami
performance. These routines were incorporated into tlie G-189A ETCLS system
simulation computer program (Reference 5} and will allow analysis of space-
craft ECLS systems containing crew appliances. Six new G-189A subroutines
were written, some of which will simulate more than one appliance concept.
They were constructed in a flexible format and with generalized input to
accommodate continuing changes in the appliance concept designs. These

2-4

D2-II8572

2.0 (Continued)

routines are written in standard Fortran V language and are operational on
the NASA JSC SRU 1108 EXEC II computing system. The component operation
and math models are described in Section 2.2.1.

In Phase 5 , the new appliance subroutines were run, both individually and
in all-up Shuttle Orbi ter and Modular Space Station ECLS systems, to verify
their accuracy and operational status within the G-189A program environ-
ment. The results have been correlated with test data where available,
and excellent agreement was obtained. Where test data v/ere not available,
the results were compared with independent analysis and found to be
reasonable and accurate. This verification effort is described in Section
2 . 2 . 2 .

During Phase 6. four development plans were generated for appliances which
indicated a need for further development. These development plans present
a proposed technical approach accompanied by a schedule to achieve the
recommended development activity. The development plans generated are
contained in Sections 2.3.1 through 2.3.3.

As an extension to the Crew Appliance Study, the task of developing a con-
ceptual design for a "freezer kit" to be placed aboard the Shuttle Orbi ter
was assigned to the Boeing Aerospace Company. The resulting freezer conceptual
design provides for frozen storage of whole food items as well as medical
samples that can be readily installed on board the vehicle for selected
orbital missions. In conjunction with Boeing's work, LTV Aerospace was
assigned the responsibility to investigate potential refrigeration units
for cooling and to provide a conceptual design compatible with the freezer
requirements. The freezer conceptual design is discussed in detail in
Section 2.1.4,

D2-IIE572

2.1 TASK 1.0, CONCEPT STUDY

This task identified' existing space-oriented crew appliance concepts using
source documentation located as a result of a thorough literature survey.
These data provided the basis to generate the appliance functions matrices
to tabulate critical data and to perform a system level integration and
optimization trade study. The results of the system optimization study
defined the optimum crew appliances system which satisfied the Shuttle
Orbiter and Space station requirements with minimum impact to the ECLSS and
vehicle configuration,

2.1.1 Source Documentation

The results of the literature search conducted during the crew appliance
study are contained within the bibliography published in Appendix A of
the Crew Appliance Concepts report. A total of 682 references are included.
Each reference was catalogued according to the type of appliance or vehicle
to which it was related. For this purpose, a filing index was constructed
to include all the types of appliances, vehicles, and related technology
used during, the crew appliance study, as shown in Figure 2.1-1. A general-
ized data handling program, COMPOSIT'77, available on the Commander-II
System of Corn-Share timesharing computer located at Ann Arbor, Michigan,
was used to store, manipulate, and retrieve this information. For each
reference, the following data were stored:

o Reference Identification Number

o Title .

o Author(s)

o Date (month/ day /year)
o Publishing Organization
o Contract Number
o NASA JSC Library Number
o Other Document Numbers

o Index Codes (from Filing Index, Figure 2.1-1)

2-6

1.0 VEHICLE REQUIREMENTS

1.1 SHUTTLE ORBITER

1.2 SPACELAB-

1.3 MODULAR AND 33-FOOT SPACE STATION

1.4 SKYLAB

1.5 SPACE TUG

' 1.5 MANNED ORBITING LABORATORY (MOL)

1.7 RESEARCH AND APPLICATIONS MODULE (RAM)

* 1.3 SPACE STATION/BASE

1.9 APOLLO APPLICATIONS PROGRAM (AAP) ;

1.10 LUNAR BASE - .

1.11 APOLLO

, T 1.12 LUNAR MODULE (LM)

_ 1.13 INTERPLANETARY MANNED MISSIONS

2.0 FOO D MANAGEMENT

2.1 FOOD STORAGE (REFRIGERATOR/FREEZER/

STORAGE MODULES)

2.2 FOOD PREPARATION

2.3 FOOD CLEANUP (DISHWASHER/DRYER, WIPES)

2.4 WORK/DINING AREAS

2.5 ANALYTICAL

3 *° PERSONAL HYGIENE. .

3.1 ' FECAL COLLECTION/TRANSFER/PROCESSING

3.2 URINE COLLECTION/TRANSFER/PROCESSING

3.3 VOHITUS COLLECTION/TRANSFER/PROCESSING

• 3.4 PARTIAL BODY WASHING/DRYING

3.5 . WHOLE BODY SHOWER

3.6 : DENTAL

3.7 SHAVING ’

3.8 HAIR/NAIL

3.9 , GENERAL PERSONAL HYGIENE ITEMS

3.10 MICROBIAL CONTROL

3.11 ANALYTICAL

4.0 ’ HOUSEKEEPING

4.1 EQUIPMENT CLEANING

4.2 TRASH COLLECTION

4.3 TRASH PROCESSING/DISPOSAL

4.4 LAUNDRY (DISPOSABLE/REUSABLE CLOTHING,

WASHER/DRYER)

4.5 WASH WATER PROCESSING

4.6 MICROBIAL CONTROL

4.7 ANALYTICAL

5..0 RECREATION

5.1 AUDIO

5.2 VISUAL

5.3 EXERCISE

6.0 MEDICAL

6.1 EXPERIMENT MANAGEMENT

6.2 PREPARATION, PRESERVATION, AND RETRIEVAL

EQU I PMENT ( REFRIGERATORS/FREEZERS/OVENS)

6.3 RADIOBIOLOGY

6.4 DENTISTRY

6.5 • MINOR SURGERY

6.6 ANALYTICAL

7 . 0 APPLIANCE-RELATED’ TECHNOLOGY

7.1 HEAT PIPES ‘ ’ ’

7.2 ULTRASONIC

7.3 MICROWAVE

7.4 LASER

7.5 - MICROBIOLOGICAL PROCESSES

7.6 DIALYSIS AND MEMBRANES

7.7 THERMOELECTRIC DEVICES

7.8 FUEL CELLS

7.9 ELECTROPHORESIS

7.10 LIGHT PIPES AND FIBER OPTICS

err

Figure 2.1-1. Crew Appliance Subject Filing Index

7.11 SPECIAL THERMAL INSULATION AND ISOLATION

7.12 BATTERIES

7.13 TANKS

7.14 MONITORING

7.15 METAL BELLOWS

7.16 FILTERS

7.17 CRYOGENIC COOLING

7.18 SEALS

7.19 SOLAR COLLECTOR

7.20 VALVES

7.21 SPACE RADIATORS

7.22 REFRIGERATION

CJI
*"■ I

Figure 2.1-1. C rev/ Appliance Subject Filing Index (concluded)

D2-1I8572

2.1.1 (Continued)

The computer program is a highly flexible tool for collection sorting,
storage, analysis, and retrieval of generalized data in optional formats.
Using this program, a complete alphabetized and sorted listing of the
entire crew appliance bibliography was obtained.

The resulting bibliography published in the Crew Appliance Concepts report
was composed of three parts.

Part I lists the title, date, publisher, and reference identification number
for each reference. The references are arranged in numerical order by
identification number. The first 299 references are numbered 1 through 299
consecutively, and represent the references reviewed in detail and used
during the crew appliance study. The following 383 references are numbered
1001 through 1383 consecutively. These references were located during the
literature search but were not directly used for the crew appliance trade
study.

In Part II ,. all the references are listed in alphabetical order by title.

With each reference is listed all the information described previously
which is stored for it in the computer.

Part III has all the references sorted by their index code(s) from Figure
2,1-1 and listed alphabetically in a shortened form (title, date, and refer-
ence identification number). Examples of each of the bibliography sections
are given in Figure 2,1-2. Thus, one can readily find (in Part III) every
reference collected for any given appliance or vehicle category in the
filing index (Figure 2.1-1). More detailed information about the references
thus located may then be found by examining the long form for the same
reference in Part II.

The information accumulated for all the references in the Crew Appliance
Bibliography described above is permanently stored on Corn-Share magnetic
tape 5398. BOEING. APPL(D=1600, T=9). These references may easily be searched.

2-9

D2-1IP572

PART I - NUHBERICAL REFERENCE LISTING

oooi * European space research organization space shuttle-spacelab discu

SSIONS# # 04/17/73# NASA-JSC

0002 « SPACE SHUTTLE SYSTEM SUMMARY# ROCKWELL QOC* SSV73-4DtR># 07/00/73
l ROCKWELL

0003 - SPACE SHUTTLE SYSTEM TECHNICAL REVIEW# ROCKWELL DOC* S3V73-26# 0*
/16/73# ROCKWELL

0004 - SPACE SHUTTLE PROGRAM REVISED CABIN STUDY# ROCKWELL DOC. SSV73-43
# 03/13/73# ROCKWELL

OOOS - ORBITER VEHICLE END ITEM SPEC* for THE SPACE SHUTTLE SYS*# PART 1
# PERFORMANCE AND DESIGN REQUIREMENTS# SPEC* NJ. MJ070-0001-1# 12/07/73#

PART II - ALPHABETICAL REFERENCE LISTING

oi &y a baseline protocol for personal

HYGIENE-FINAL REPORT
ANON# FAIRCHILD

. Ois/3l/7i# MAS D-llSCy# FRO 3589/ T71-1S611
3*10

•1001 A OIumECICaL PROGRAM FOR
extended space missions
anon# NAiin-'JSC
Ob/OO/69# # # T73-11082

6*0

0229 A DEVICE FOP STORING AMO DISPENSING
BITE-SIZE FOLD CLUES

J L fiDDR’E# J R lATkINj M 0 ROTH# WHIRLPOOL
07/13/71# F*jie>ui>-69-C# SAM-TR-71-33# N72-15485
2*1

1002 A MICROBIAL SURVEILLANCE
SYSTEM

A K pRYOR AND C'R.KC DUFF# FAIRCHILD
OO/Ol/ 68 # # #

6*0

PART III - REFERENCES SORTED BY FILING INDEX

2.0 FOOD MANAGEMENT

A nlcROWAVE FEEDING system for ExTEJCEO SPACE MISSIONS# 12/69# 1003

A ST-j-dy OF 'THE REACTION KInETICS FOR SEVERAL SPACECRAFT LIFE SUPPORT Sy$
TENS# OOA-O# 10&U

’ ACCEPT (ovCC TEST FOR LM OXYcEN BACTERIA FILTER# 03/68# lOlO

ADVANCED METHODS GF RECOVERY FOR SPACE LIFE SUPPORT SYSTEMS# 00/73* I0l3

analysis cP selected constituents in space food# oo/oo# iois

Figure 2.1-2. Examples of the Crew Appliance Bibliography Sections

D2-ll£572

2.1.1 {Continued}

sorted* rearranged or added to by using the COMPOSITE program. User in-
structions for operating the program are also provided in the bibliography
published in the Crew Appliance Concepts Report.

2.1.2 Concept Study Results

An Appliance Concept Function Matrix was developed to describe the physical
and operational parameters for each appliance concept. Formatting of the
matrix was designed to include and properly present parameters which have
an impact on a vehicle ECLSS. Appliance concepts included in the matrices
were organized within an appliance system to facilitate indexing of each
concept. Appliance concept data presented in the matrices were adjusted
to reflect Shuttle Orbiter and Modular Space Station mission requirements.

The Shuttle Orbiter and Modular Space Station baseline mission and timeline
were developed using the latest available reference data.

2.1.2. 1 Mission Baseline Description

Shuttle Orbiter and Modular Space Station baseline missions are presented
in Figures 2.1-3 and 2.1-4, respectively. Mission timelines for the two
spacecraft are shown in Figures 2.1-5 and 2.1-6. The Shuttle Orbiter mission
baseline was referenced from the 1973 fourth quarter Rockwell International
mission description (Reference 6). The Modular Space Station mission base-
line was compiled from McDonnell Douglas, Rockwell International, Hamilton
Standard, and NASA JSC study reports.

The Shuttle Orbiter baseline mission provides for a maximum of six crew-
members for 7 days. Vehicle capability must, however, be based on the
nominal mission plus contingencies in order to specify a complete appliance
concept. Shuttle Orbiter contingency is specified as 96 hours for up to
10 crewmen. The appliance study was, therefore, based on a 42 man-days
nominal mission plus 40 man-days contingency or 82 man-days (20.5 days with
a nominal four-man crew}. The timeline used as a baseline for daily crew
activity was based on the mission requirements (Reference 6).

2-11

D2418572

SHUTTLE MISSION BASELINE

o 150,000 POUND QRBITER
o BASELINE MISSION

- 42 MAN-DAYS {3-6 MALE/FEMALE CREW FOR 7 DAYS)

- 4 MAN NOMINAL MISSION

o VEHICLE SYSTEM CAPABILITY

- 42 MAN-DAYS + 96-HOUR CONTINGENCY FOR UP TO 10 CREWMEN
(40 MAN-DAYS)

SHUTTLE IMPOSED REQUIREMENTS ON THE APPLIANCE SYSTEM
0 ALL MISSIONS WILL USE SAME HABITABILITY FUNCTIONS
o GRAVITY - ZERO TO ONE EARTH GRAVITY
o ATMOSPHERE

- PRESSURE 14.7 PSIA

. - COMPOSITION 3.2 PSIA 0 2

11.5 PSIA N 2

- C0 2 CONCENTRATION 0-7.6 mm Hg

o TEMPERATURE .

- RANGE (DRY BULK) 65 t ’-80°F

A MEN (DESIGN PT.) 70° F

10 MEN (DESIGN PT.) 80" F

- DEWPOINT - 39° -61" F

o OPERATIONAL LIFE

- 10 YEARS/100 ORBITAL MISSIONS/REPLACEABLE UNIT CONCEPT
o GENERAL

- GAS VENTING ALLOWED/NONPROPULSIVE

- LIQUID VENTING SHALL BE MINIMIZED/NONPROPULSIVE

- JETTISON OF SOLIDS/SOLID WASTES SHALL NOT BE ALLOWED.

- NO MEDICAL SAMPLING REQUIRED OF FECES/URINE

SHUTTLE TIMELINE

o NOMINAL CREW TIMELINE (SEE FIGURE 2.1-5)

- WORK (INCLUDING OFF-DUTY) - 13 HOURS )

- EAT - 3 HOURS > REFERENCE 7

- SLEEP - 8 HOURS \

Figure 2.1-3. Shuttle Baseline Mission

; , 2 - 12 . ; : .; ... ;.

D2-1I8572

SPACE STATION MISSION BASELINE

o 20,000 POUND MODULES (MAXIMUM)

0 BASELINE MISSION

- 6-MAN CREW "(MALE/FEMALE)

- 90/180-DAY RESUPPLY

o VEHICLE SYSTEM CAPABILITY

- 1080 MAN- DAYS + 96 HOUR CONTINGENCY FOR UP TO 12 MEN

SPACE STATION REQUIREMENTS IMPOSED ON THE APPLIANCE SYSTEM

o GRAVITY - ZERO
o ATMOSPHERE (LIVING QTR's)

- PRESSURE 14.7 PSIA

« COMPOSITION 3.2 PSIA 0 2

11.5 PSIA N 2

- C0 2 CONCENTRATION

o TEMPERATURE (LIVING QTR's) *

- RANGE (DRY BULK) 65° -75° F

- DEWPOINT 39° -62° F

0 OPERATIONAL LIFE

- 10 YEARS/SCHEDULED MAINTENANCE ■ - ’

o GENERAL '

- GAS VENTING ALLOWED/NONPROPULSIVE

- LIQUID VENTING SHALL BE MINIMIZED/NONPROPULSIVE

- JETTISON OF SOLIDS/SOLID. WASTES SHALL NOT BE ALLOWED

SPACE STATION TIMELINE

o NOMINAL CREW DUTY CYCLE

- SEE FIGURE 2.1-6

Figure 2.1-4. Space Station Baseline Mission

2-13

ORIGINAL PAGE 33
OF FGGR QUALITZ

y '■

\ y

ITT^ DARKNESS

PHASING

launch] plane CHANGE

T'-rn

10 . 12 * 14

Time from lift-off* hr

, 3™,DAYLIGirr

PHASING isx COELUPTIC 2110 •
CORRECTION . COELUPTIC

tmii HEIGHT

J HU ADJUST CORRECTIVE

j COM3 1 NATION W .

[ J t.-T C i i * l i \

~r 1 — - — r i , ■

16 18 20 22 24

’ OO.CK

xpr

SERVICING

OPERATIONS

■rw L r

26 • 28

34 36 38

Time from lift-off,* hr

SEPARATION
• UNDOCK

"eat] SERVICING OPERATIONS .[eat]

:ji,

40 42 44* 46 4B

CIRCULARIZATION

OAIl I BEGIN SORTIE niTTl
• OPERATIONS m

52 54

SLEEP ■ •

? 1] » ^ * yl

58 60 62
Time from lift-off, - hr

EAT SORTIE - OPERATIONS EAT

(a) Launch to 72 hours*

Figure 2.1-S. Shuttle Orbiter Timeline

2I3311-2Q

D2-I18572

2. 1.2.1 (Continued)

The Modular Space Station baseline mission uses a nominal six-man crew for
180 days. Mission contingency is based on 96 hours for six men. A total
vehicle capability of 1104 man-days or 184 days was used for the appliance
study. Space Station resupply period was assumed to be 180 days. The
timeline used as a baseline for daily crew activity was based on the mission
requirements and was taken from Reference 8. This timeline v/as modified
as required to incorporate the various appliance functions involving crew
time during the Crew Appliance System Optimization phase of the study.

Also, timelines were altered to reduce the appliance system peak thermal
and power demands on the vehicle systems.

In addition to the ECLSS imposed appliance restrictions, liquid and gas
venting from appliances v/as minimized or eliminated and jettison of solids/
solid wastes was not allowed. Gas or liquid venting, when allowed, was
assumed to be nonpropulsive. The Shuttle Orbiter personal hygiene appliance
concepts do not include hardware required to provide medical sampling of
crewman feces/urine.

2. 1.2. 2 Appliance System Description

Development of a crew appliance system organization v/as necessary to
thoroughly and orderly categorize all of the appliance concepts. The
system organization is summarized in Figure 2.0-1. The Crew Appliance
System was subdivided into three -major groupings: Habitability Subsystem,

Habitability Function, and Appliance Function. The five habitability sub-
systems are food management/personal hygiene, housekeeping, off-duty
activity, and medical. These subsystems were further subdivided into 13
crew habitability functions and appliance functions then identified for
each. A total of 33 appliance functions were included in the study.

Engineering data were derived for each concept listed in the Appliance
Function section using the reference data described in Paragraph 2.1.1,

NASA JSC and MSFC personnel, and crew appliance/space vehicle contractors.

.2-16

D2-JIS572

2. 1.2. 2 (Continued)

New concepts were also added as they were identified during the study.

A total of 135 individual appliance concepts considered during the study
are listed in Figure 2.1-7 by title.

Appliance concept engineering data were normalized to the Shuttle Orbiter
and Modular Space Station baseline mission requirements. These data were
arranged and are presented in Appendices B and C of the Crew Appliance
Concepts Report by individual appliance concept descriptions and work
sheets. Appendices B and C apply to Shuttle Orbiter and Modular Space
Station, respectively. The work sheets provided identification of each
crew appliance concept weight, volume, electrical power, and thermal
requirements. '

In addition to these basic data, the solid/gas/liquid expendables require-
ments and operational penalties, if applicable, were computed and were also
presented in the work sheets. A schematic or outline drawing, in most
cases, and a summary of the references from which the engineering data were
derived accompany each concept description.

2. 1.2. 3 Appliance Concept Function Matrix

Engineering data derived for each appliance concept described in the
previous Paragraph 2. 1.2.2 were formulated into an Appliance Concept Function
Matrix. The results of these concept analyses are summarized, by appliance
function, in the matrices included in Tables 3-1 through 3-29 for Shuttle
and Tables 3-30 through 3-59 for Space Station in the Crew Appliance Concepts
Report.

The Appliance Concept Function Matrix was developed, organized, and com-
piled to completely assess each concept's impact on the space vehicle
mission operation and particularly on the vehicle ECLSS and to provide the
necessary data for trade studies.

2-18

\ i

1.0 FOOD MANAGEMENT

1.1 FOOD STORAGE

1.1.1

1 . 1 . 1.1
1 . 1 . 1.2

Ambient Food Storac

Rigid Containers
Flexible Containers

1 . 1.2

1.1. 2.1 Space Radiator

1.1. 2. 2 Thermoelectric

1.1. 2.3 Air Cycle Turbine/Compressor

1.1.3 Frozen Food Storage

1. 1.3.1 Space Radiator

1. 1.3.2 Thermoelectric

1. 1.3.3 Air Cycle Turbine/Compressor

1.2 FOOD PREPARATION

1.2.1 Food Reh.ydration

1.2.2 Food Harming

1.2. 2.1 Heating Trays (Skylab)

1.2. 2. 2 Oven - Hot Air Convention (Electric Heat)

1.2. 2. 3 Oven - Microwave

1.3 GALLEY CLEANUP

1.3.1

1.3. 1.1 Hot Water Spray - Centrifuge Drying
1.3* 1.2 Hot Water Spray - Air Spray Dry

1.3. 1.3 Hot Water Spray Wash - Force Hot Air

Electric Heat Dry

1.3. 1.4 Hot Water Spray Wash - Forced Cold Air

Desiccant

1.3. 1.5 Hot Water Spray Wash - Forced Hot Air

Dry - Thermal Storage

1.3. 1.6 Ultrasonic Wash - Centrifuge Drying

1.3. 1.7 Ultrasonic Wash - Forced Hot Air

Electric Dry

1.3. 1.8 Ultrasonic Wash - Force Cold Dry Air

Desiccant, Electrically Desorbed

1.3. 1.9 Ultrasonic Wash - Force Hot Air Dry -

Thermal Storage

1.3.1.10 Manual Wash - Manual Wipe Dry

1.3.2 Dishwasher/Dryer with Dishes

1.3 .2.1 Hot Water Spray - Centrifuge Drying

1.3. 2. 2 Hot Water Spray - Forced Hot Air Electric

Heat Drying

1.3. 2. 3 Hot Water Spray - Forced Air/Desiccant/

Electrically Heated

1.3. 2. 4 Manual Wash - Manual Wipe

1.3. 2. 5 Disposable Cups - Reusable Metallic

Utensils and Dishes

1.3. 2.6 Disposable Cups and Nonmetallic Dishes -■

Reusable Metallic Utensils

1.3. 2. 7 Disposable Cups and Nonmetallic Utensils -

Reusable Metallic Dishes

1.3. 2. 8 Disposable Cups and Nonmetallic Utensils

and Dishes

1.3. 2. 9 Reusable Cups and Metallic Utensils

and Dishes

1.3.2.10 Reusable Cups and Metallic Utensils -

Disposable Nonmetallic Dishes

1.3.2.11 Reusable Cups ar.i Metallic Dishes -

Disposable Nonmetallic Utensils

1.3.2.12 Reusable Cups-Disposable Nonmetallic

Utensils and Dishes

2.0 PERSONAL HYGIENE

2.1 WASTE COLLECTION/TRANSFER

2.1.1 Fecal Coll ecti on/Transfer

Figure 2,1-7- Crew Habitability and Appliance Functions and Concepts

D2-11S572

61-2

2. 1.1.1 Dry John

2. 1.1. 2 Dry John - Anal Wash
2. 1-1-3 Germicide - Wet John

2. 1.1.4 Integrated Vacuum Decomposition

2. 1.1.5 Flush Flow 02 Incineration

2. 1.1.6 Pyrolysis/Batch Incineration

2.1. 1.7 Wet Oxidation

2. 1.1.8 Semiautomatic Bag System (Skylab)

2. 1.1.9 Dry Bags (Apollo)

2.1.2 Urine Collection/Transfer

2. 1.2.1 Standup Urinal

2. 1.2.2 Commode Urinal

2.1. 2. 3 Intimate Male Adapter Urine (Skylab)

2. 1.2. 4 Aperture Urinal

2. 1.2.5 Liquid/Gas Flow Cuff Type (Apollo)

2.1.3 Vomltus Coll ecti on/Transfer

2.1.3. 1 Disposable Intimate Personal Adapter

(Mates with .Commode)

2. 1.3.2 Reusable Intimate Personal Adapter, Lined

(Mates with Commode)

2.1. 3. 3 Disposable Portable Collector

2. 1.3. 4 Reusable Portable Collector

2.2 BODY CLEANSING

2.2.1 Whole Body Shower

2. 2. 1.1 Vacuum Pickup ' ‘

2. 2. 1.2 Air Drag (Evaporative)

2.2. 1.3 Mechanical (Towel Pickup)

2.2. 1.4 Collapsible

2.2.2 Partial Body Washing

2.2.2. 1 Disposable Wet Wipes

2. 2. 2. 2 Reusable Wet Wipes

212.2.3 Disposable Wipes (Prepackaged)

2. 2. 2. 4 Automatic Sponge

2. 2. 2. 5 Reusable Washcloths

2. 2. 2.6 Disposable Washcloths (Skylab)

2.2.3 Partial Body Drying

2. 2. 3.1 Reusable Dry Wipes

2. 2. 3. 2 Disposable Dry Wipes

2. 2. 3. 3 Electric Dryer

2.3 PERSONAL GROOMING
2-. 3.1 Shaving

2. 3. 1.1 Wet Shave - Safety Razor and Cream

2. 3. 1.2 Dry Shave - Electric Razor/Vacuum

Collection

2. 3. 1.3 Dry Shave - Windup Razor (Skylab)

2. 3. 1.4 Dry Shave - Vacuum Motor-Driven Razor

2. 3. 1.5 Wet Shave - Safety Razor/Vacuum

Collection

2.3.2 Hair Cutting

2. 3.2.1 Electric Clipper/Vacuum Collection

2. 3.2. 2 Razor-Comb/Vacuum Collection

2.3.3 Nail Care

2. 3. 3.1 Manual Nail Clipper/Bag Collection

2. 3. 3. 2 Metal Nail File/Vacuum Collection

2.3.4 Dental

2.3.4. 1 Toothbrush with Dentifrice

2. 3. 4. 2 Water Pix

2. 3. 4. 3 Electric Toothbrush with Dentifrice

3.0 HOUSEKEEPING

3.1 EQUIPMENT CLEANING

3.1.1 Surface Wiping

3. 1.1.1 Disposable Wet/Dry Wipes

Figure 2.1-7. Crew Habitability and Appliance Functions and Concepts (continued)

D2-I18572

2-20

3. 1.1. 2 Reusable Wet/Disposable Dry Wipes

3. 1.1.3 Disposable Wet/Dry Wipes (Prepackaged)

3.1. 1.4 Automatic Mop

3 . 1.1.5 Reusable Cleaning Cloths/ Disposable Dry

Wi pes

3. 1.1.6 Disposable Cleaning Cloths/Disposable Dry

Wi pes

3. 1.1. 7 Disposable Wet Wipes/Reusable Dry Wipes'

3.1. 1.3 Reusable Wet/Dry Wipes

3. 1.1.9 Reusable Cleaning Cloths/Dry Wipes

3.1.1.10 Disposable Cleaning Cloths /Reus able Dry

Wipes

3.1.1.11 Sponges

3.1.1.12 Sponges/Skylab Wetting Unit

3.2 REFUSE MANAGEMENT

3.2.1 Manual Collection

3. 2. 1.1 Waste/Trash Bags

3.2. 1.2 Waste Receptacles/Reusable

3.2. 1.3 Waste Receptacles/Disposable

3.2.2 Vacuum Collection

3. 2. 2.1 Portable Vacuum/Electric (Skylab)

3. 2. 2. 2 Portable Vacuum/Electric (Commercial)

3. 2. 2.3 Portable Vacuum/Space Venting

3.2.3 Refuse Transfer

3.2.4 Refuse Processing

3. 2. 4.1 Compactor

3. 2. 4. 2 Shredder

3. 2. 4. 3 Incinerator

3. 2. 4. 4 Integrated Vacuum Decomposition

3. 2. 4. 5 Flush Flow 02 Incineration

3.2. 4.6 Pyrolysis/Batch Incineration

3. 2. 4. 7 Wet Oxidation

3.2.5 Refuse Disposal /Storage

3. 2. 5.1 Vacuum Storage

3. 2. 5. 2 Storage Bin/Container

3. 2. 5. 3 Restorage/Biological Stabilized

3.2. 5. 4 Trash Rocket

3.3 GARMENT/LINEN MAINTENANCE

3.3.1 Garment/Linen Washing

3. 3. 1.1 Mechanical Os- illations

3. 3. 1.2 Fluidic Agitation

3. 3. 1.3 Piston Agitation

313.1.4 Cyclic Valve and Pump

3. 3. 1.5 Diaphragm Actuated - One Directional

Squeeze

3. 3. 1.6 Diaphragm Actuated » Two Directional

Squeeze

3. 3. 1.7 Water Spray Agitated

3.3. 1.8 Ultrasonic

3. 3. 1.9 Manual Washboard

3.3.1.10 Plain Recirculation

3.3.2

3. 3. 2.1

3. 3. 2. 2

3. 3. 2. 3

3. 3. 2. 4

3.3. 2. 5

3. 3. 2. 6

3.3. 2. 7

3. 3. 2. 8

3. 3.2.9

3.3.3
3.3. 3.1

Garment/Li nen/Dryi ng

Forced Hot Air - Electric

Forced Hot Air - Heat from Thermal Storage
Unit

Force Cold Dry Air - Desiccant - Vacuum
Regenerable

Force Cold Dry Air - Desiccant - Heat
Regenerable

Vacuum Dry

Thermal Vacuum Dry - Electric Heat

Thermal Vacuum Dry - Thermal Storage/

Radiant Heat

Clothesline - Forced Convection

Clothesline - Forced Convection plus
Electric Heat

Garment/Linen Washer/Dryer-Disposable Clothes

Fluidic Agitation/Forced Hot Air - Electric
Heater

\ Fiqure 2.1-7. Crew Habitability and Appliance Functions and Concepts (continued)

O'!

,PO

Fluidic Agitation/Forced Hot Air -
Thermal Storage Heated
Fluidic Agitation/Forced Air Drying -
Clothesline

Fluidic Agitation/Forced Air Drying -
Clothesline

Water Spray Agitation/ Forced Hot Air
Electric Heater

Water Spray Agitation/Forced Hot Air
Thermal Storage Heater
Water Spray Agitation/Forced Air
Drying “Clothesline
Water Spray Agi tati on/Electri cal ly
Heated - Clothesline
Disposable Clothes

WASH WATER PROCESSING

OFF-DUTY ACTIVITIES

ENTERTAINMENT

Mus 1 c

Cassette PTayer/Recorder

l ibrary

Books

Television

Games

Handball
Dart Board
Cards

PHYSICAL CONDITIONING

4.2.2 Hand Exerciser

5.0 MEDICAL

5.1 STERILIZATION

5.1.1 Autocl aves

5. 1.1.1 Moist Heat

5. 1.1.2 Dry Heat

5. 1.1.3 Ethylene Oxide

5.2 PHYSICAL MONITORING
5.2.1 Ergometer

fig

2f|

Q S

“S

Figure 2.1-7. Crew Habitability and Appliance Functions and Concepts (concluded)

D2-H8572

D2-1I8572

2. 1.2.3 (Continued)

The matrix identifies the appliance concepts in the first column, see
example. Figure 2.1-8. Usage time is specified in uses per day and hours
per use in order to provide rate data for future work. The consumables
and flow requirements columns specify the type of fluid, amount consumed
per use, flow rate, pressure, and temperature required of the ECLSS by the
appliance concept. Thermal requirements are divided into coolant and heat
leak requirements for use in estimating the appliance concept impact on
ECLSS thermal designs. The coolant thermal requirement was defined as
latent and sensible heat required to be removed at an appliance/ECLSS
coolant interface. Heat leak thermal requirement is the latent and sensible
heat required to be removed at the ECLSS cabin heat exchanger. The elec-
trical power requirements identify the peak and average AC and DC power
requirements for each appliance concept. These data can be used to aid
the selection of a vehicle power system including inverters. Height and
volume requirements specify the total weight and volume for each appliance
concept including its solid, liquid, and gas expendables requirements which
are mission dependent. Development cost is specified by ^he appliance
concept availability; i.e., available, state of the art, etc., and cost
indicator v.'hich is based on the appliance concept complexity. The resupply
column applies only to the Modular Space Station. Resupply is the con-
sumable weight necessary for the appliances to function for an additional
180 days. The remainder of the data matrix described previously are based
on the referenced mission of 184 days for Space Station and 20.5 days for
the Shuttle Orbiter. A more detailed description of each of these parameters
is contained in the Crew Appliance Concepts Report.

The matrix for each appliance function with its accompanying set of concept
descriptions and work sheets, located in Appendices B and C of the Crew
Appliance Concepts Report, provide a complete background for the. derived
appliance data. These data were used as the basis for the trade studies
conducted to select the optimum crew appliance concepts.

2-22

2-23

r'*' . .

i .

APPLIANCE CONCEPT FUNCT l OH MA 7 H 1 x

jN&EJL.HO. .1* J ,2. •■»«-._R£F*:GEN*7 EOJ , Ood .STORAGE (SPACE STATION],

« .T

_Co*CCp.t__ysAGE .CoNSVHA8UEs_A/<5)-ri.o»_REl } OlREHENts_

NO «' ?!"E

*****

„THErMAL_rE(}HTS-

-EL.EC.pKR .rEoHTS — ttT/VoL_REQHTTS .^OEVELoJi M ENT-_nESURpLJL

COST

I o

OSES/DAT.

HRS /USE

art* Pic p«R ’AVq pwR

„TYPE .USED FLO" PRESS _ TEMP COOLANT HT LEAK *C AC HEIGHT VOLURE .AVAIL INDEX WEIGHT

<*| «KGAuSE« • -HHHG- -DEG C- -WATTS- -WATTS- DC DC -KG- -CU R- !•**) -KG-

_tLB/USEl_ L* I LP.S15)„COEG_EL— -• BTO^HR J„laT u /HR J -«aTt5.,__..K aTtST »LaS>_ICV_FT I . , lLaS1._

• 000
.009

-I.OoOO .

I .OOOOH

-.□0 -

-. 0 -

<UG.

too) ( to) t *io.oi i

. .52, —
179-1

D*-

t 0* >

.50*0 .

'.0

.*0-^,— 136*1 *62—4

•0 t 300*0) t 22*00)

>000

• 000..

t3o*

jL_.v*t 3 ,

- 9 * * 0

-»3D . J 22&*0

*0 ' 152*9

-*0.— t. 337*0)-. 1-2S* lo),

.3 —

.000

.206 1 1 .

I 7039.)

— 435 , „ — 1 1000*0.

ims.i \o

-iO .235*9 2*n'f„

*0 t 520*0) I ?2«00)

appliance

CO*'CEPX_

NO,

(*)

CONCEPT hare

{CIRCULATED}, UTERS/5EC {FT 3 /MW)

1 •

- 2 —*.

3 -

space radiator
..therhqelectric-

A1R CTCLE-TURBINE/COHPRESSOR

sncr

1 - CABIN AIR

2 - CABIN AIR (LOST) . KG/HR

3 - OXYGEN LOST) , KG/KR

4 - COOLING HATER {CIRCULATED}. KG/HR

-**i &

5 - HATER
G - NITROGEN

7 - NITROGEN

8 - FREON

9 - HATER

(LOST) , 7.G/HR
(CIRCULATED), KU/HR
(USED) , KG/KR
(CIRCULATED), KG/HR
{PROCESSED) , KG/HR

(LB/HR)

LB/HR)

{ls/hr)

(LO/KR)

(LB/HR)

(lb/hrJ

(LB/HR)

• k

("M AVAIIAPLE

(1) AVAILABLE

(2) STATE OF THE ART

(3) SOME DEVELOPMENT REQUIRED

(4) EXTENSIVE DEV. REQUIRED

(***) COST
INDICATOR

0-255

25-505

50-755

75-1005

Figure 2.1-8. Example - Appliance Concept Function Matrix

» G

«0»

• 0

-ifl).

cr~

C 7

J..

D2-HS572

2.1.3 Description of Selected Appliances

Shuttle and Space Station requirements for crew appliances were developed
from the source documentation discussed in Paragraph 2.1.1. Requirements
for each habitability subsystem were developed from the component habit-
ability function requirements, and the resulting subsystems requirements
were combined to form the basis of the total appliance system requirement
of each spacecraft. Basic appliance system requirements defined are: heat
rejection, electrical power, weight, and volume. The rationale behind each
habitability function requirement, and the appliances which are included,
are discussed in detail in the Crew Appliance Concepts Report. Optimum
appliance concepts were selected using a weighed trade-off study and were
further optimized by a comp*arison of the appliance functional requirements
to the appliance subsystem and system' requirements.'

2, 1.3.1 Vehicle Crew Appliance Requirements

The Shuttle Orbiter vehicle requirements for crew appliances were determined
exclusively from those described in Reference 9. Most of the data documented
in Reference 9 were developed for a baseline mission of 42 man-days (14 men
and three days); therefore, alterations were made to the requirements data
to make it representative of the 82 man-day mission assumed for this study.

The resulting Shuttle appliance system requirements are tabulated in
Table 2.1-1. The total requirements listed at the bottom of the table
represent the summation of all the subsystem requirements developed in the
following paragraphs with the exception of heat rejection and electrical
power. For these requirements, it was assumed that the heating and electrical
loads for the housekeeping subsystem (electric vacuum cleaning) would not
be imposed coincidentally with those of food management and personal hygiene.

The Space Station vehicle appliance requirements listed in this section
were determined from those described in Reference d. Most of the data docu-
mented in this reference were developed for a baseline mission of 180 man-days

. 2-24

HABITABILITY

SUBSYSTEM

FOOD MANAGEMENT
PERSONAL HYGIENE
HOUSEKEEPING
OFF DUTY

*- OMITTED FROM TOTAL

SYSTEM TOTAL

HEAT REJECTION

ELECTRIC POWER

WEIGHT

COOLANT

■ HT LEAK

PEAK

AVG

DEMAND

WATTS

(Btu/hr)

WATTS

WATT- HR
DAY

(lbs)

8.4

(28.6)

893.0

TBD

1201.0

• 38.4
( 84.7}

165.0
( 563.1)

805.0

TBD

636.6

588.4

(1297.2)

60.1
*( 205.2)

*80.0

60.0

120.0

41.0
( 90.4)

. 165.4
( 564.4)

250.0

TBD

740.0

85.5
( 188.5)

D2-1I8572

2. 1.3.1 (Continued)

(six men and 30 days); therefore, alterations were made to the data to
make it representative of the 1104 man-day mission assumed for this study.

Resulting Space Station appliance system requirements are tabulated in
Table 2.1-2. Total requirements listed at the bottom of the table represent
the summation of all the subsystem requirements developed in the following
paragraphs. The same format used to describe the Shuttle requirements with
appliances grouped into subsystems was also used for these requirements.

2. 1.3. 2 Weighted Trade Study

Optimum appliance concepts were selected from the Appliance Concept Function
Matrices described in Paragraph 2.1.2 using the results of a weighted trade-
off study. In addition to the operational parameters summarized in the
Appliance Concept Function Matrix, the appliance concept reliability,
maintainability, and safety were also included as evaluation criteria for
selecting the optimum concept. Crew preference, convenience, and usage
time were not factored into the trade study so that the optimum choice could
be based only on "hard" data. Crew considerations are taken into account
during the final appliance subsystem and system optimization study. The
above-mentioned selection parameters were each apportioned points to make
up a weighting distribution. Once the weighting distribution was established,
the appliance concept selection then depended on the rationale used to ratio
each parameter to its point allotment. A computer program was developed
utilizing the weighting distribution and the appliance concept selection
rationale to automatically perform the weighted trades and determine the
relative ratings of the appliance concepts.

Selection of the optimum appliance concept utilizing a weighting technique
requires that the trade parameter weighting distribution be consistent
with vehicle requirements and program goals. Numerous references were con-
sulted to develop the weighting distribution technique, and finally an

2-26

TABLE 2.1-2

SPACE STATION APPLIANCE SYSTEM REQUIREMENTS

HEAT REJECTION

ELECTRIC POWER

WEIGHT

VOLUME

HABITABILITY

COOLANT

HT LEAK

PEAK

AVG

DEMAND

SUBSYSTEM

WATTS

(Btu/hr)

WATTS

(Btu/hr)

WATTS

WATT-HR

DAY

(lbs) .

M 3

(ft 3 )

FOOD MANAGEMENT
» •

958.0

(3269.7)

TBD

958.0

TBD

532.2

(1173.3)

6.313

(222.9)

PERSONAL HYGIENE

299.0

(1020.4)

TBD

299.0

TBD

287.3
( 633.3)

2.852

(100.7)

HOUSEKEEPING

14.0

TBD

14.0

TBD

267.5
( 589.8)

2.530
{ 91.1)

OFF-DUTY

•

TBD

170.1
( 375.0)

3.398 '
(120.0)

SYSTEM TOTAL

•

TBD

■tNM

15.142

(534.7)

D2-1IS572

D2-118572

2. 1.3.2 (Continued)

analytical comparison was made to a previous study (Reference 10) to provide
a proper weighting distribution. The study. Reference 10, provided an
in-depth trade study of various clothes washer concepts. Study results
selected, as the optimum concept, a water spray agitated clothes washer
for a Space Station having a resupply period of 230 days. The appliance
concept selection program was adjusted to use a 230-day resupply period.
Selection program runs were made for disposable clothes and eight clothes
washer concepts using four different weighting distributions. The results
of these runs were plotted to determine which distribution would select
water spray agitation as the optimum concept. An even weighting distribution
(all parameters having the same point value) vos used as the basis for
comparison to three independent weighting distributions. The weighting
point distributions were varied to accentuate the more important
parameters — cost, weight, volume, and thermal requirements. The
weighting chosen was selected to place the heaviest emphasis on cost.

A detailed description of the weighting distribution rationale is con-
tained in the Crew Appliance Concepts Report.

2. 1.3. 3 Crew Appliance System Optimization .

Results of the weighted trade study provided an initial list of appliance
concepts which individually best satisfy the electrical, weight, and volume
requirements for the Shuttle and Space Station missions with a minimum
thermal penalty to the spacecraft's ECLSS. The optimized appliance systems,
which will, as an aggregate of these concepts, or alternates, provide
appliance systems which best satisfy each vehicle’s requirements.

Optimization of the Shuttle and Space Station appliance systems was initiated
by first assembling the habitability subsystem with appliance concepts chosen
in the trade studies. Heat rejection, electrical power, weight, and volume
characteristics of the optimum subsystem were compared to the vehicle sub-
system requirements; and when deficiencies existed, concepts were exchanged
to reduce them. In some instances, crew convenience was an overriding
factor in the concept selection. Once the deficiencies were reduced to a
minimum, the subsystems were incorporated into the total appliance system.

2-28

D2-1IE572

2. 1.3. 3 (Continued)

Characteristics of the optimized appliance system were compared to the
total spacecraft appliance system requirements, and again the appliance
concept selection was reviewed to reduce system deficiencies where they
existed. The optimum crew appliance system is comprised of the final
appliance concepts chosen in this process. Procedures used in the process
are discussed in detail for the Shuttle and Space Station in the Crew
Appliance Concepts Report. Detailed descriptions and performance data of
the concepts chosen and those considered in the trades are included in
Appendices B and C of the above mentioned Concepts Report.

The final selected concepts for each habitability function in the Shuttle
and Space Station appliance systems are tabulated in Table 1.1-1 and
Table 1.1-2, respectively, located in the Summary, Paragraph 1.0. A brief
description of each of the selected concepts for the Shuttle and Space
Station is contained in Paragraphs 2. 1.3. 4 and 2. 1.3.5, respectively. A
summary of thermodynamic, electrical power, weight, volume, and consumables
and flow requirements is contained in Table 2.1-3 for the Shuttle and in
Table 2.1-4’ for the Space Station vehicle.

2. 1.3. 4 Selected Shuttle Appliance Concepts

The appliance system selected for the Shuttle Orbiter is described in the
following paragraph. A summary of thermodynamic, electrical power, weight,
volume, and consumables and flow requirements for each of these selected
appliances is contained in Table 2.1-3.

2-29

PERSONAL .HYGIENE ... FOOD MANAGEMENT [W

. 3 *1

o o

**f w

’ ►cJ

& ts

<A- / * r

TABLE 2.1-3 SHUTTLE APPLIANCE CONCEPT SUMMARY FUNCTION MATRIX
I USAGE CONSUMABLES AND FLOW ^EOuTpB^ENTS THERMAL REQMTS ELEC PWR REOKTS WT/VOL P.EOMTS

HABITABILITY

FUNCTION

APPLIANCE

FUNCTION

CONCEPT

CHOSEN

USES/DAY

HRS/USE

TYPE

'(*}

AMT.

USED-

-KG/USE-

(LB/USE)

FLOW

(*)

PRESS

-NPHG-

TEMP
-DEG C-
( PEG F)

COOLANT

-WATTS-

{BTU/HR)

HT LEAK
-WATTS-
(RTH/HR)

PK PWR
AC

-WATTS-

AVG PWR
AC
DC

-WATTS-

WEIGHT

^-KG-

VOLUME
-CU M-
fru ft)

FOOD

STORAGE

REFRIGERATED

SPACE

RADIATOR

.000

8’ ’

.0000

(.0000)

-.00

( .00)

(.0)

4.4

(40.0)

(30.)

41.

(Ml.)

50.0

.,0

8.9
{ 19.6)

.04
( 1.44}

FOOD .
PREPARATION

WARMING

HEATING

TRAYS

3.000

2.000

(0.)

197.

(672.)

660.0

197.0

36.6

(80.6)

.14
( 4.80)

GALLEY DISH

CLEANUP CLEANUP

HASTE :
COLLECTION

BODY

CLEANSING

PERSONAL

GROOMING

REUSABLE
DISHES &
UTENSILS
WITH

DISPOSABLE
.WET/ DRY
WIPES

( 0 .)

.0 15.5 .03

.0 (34.2) ( 1.20)

FECAL/

DRY

4.000

,0000

9.44

21.1

200.

— ,

675.0

440.0

107.3

.85

URINE

JOHN

.150

(.0000)

(20.00)

(.0)

(70.0)

( 0.)

(683.)

62.0

52.0

[236.5)

(30.00)

COLLECTION

SYSTEM

.0000

.00

21.1

(.0000)

( .00)

(.0)

(70.0)

V OH, ITUS

DISPOSABLE

.560

.no

COLLECTION

BAGS

.016

( 0.)

( o.)

( 1.2)

( -01)

PARTIAL

DISPOSABLE

40.000

. .0

43.5

.06

CODY

WET

.037

( 0.)

{ 96.0)

{ 2.20)

WASHING

WIPES

PARTIAL

DISPOSABLE

40.000

.0111

.00

” .0

19.6

.17

BODY

DRYING

DRY

■

.056

(.0245)

( .00)

(.0)

( .0)

( 0.)

[ 43.3)

( 5.89)

SHAVING

SAFETY

4.000

1.0

.00

.100

( 0.)

( 2.1)

( .08)

WINDUP

4.000

.00

•

.100

( 0.)

( O.J

{ 1.0)

{ .02}

DENTAL

TOOTHBRUSH

16.000

6.4

.03

CARE

WITH ;

.082

( 0.)

(14.0)

( 1.20)

DENTIFRICE!

2-31

TABLE: 2. 1-3 SHUTTLE APPLIANCE CONCEPT SUMMARY FUNCTION MATRIX (CONT.)

USAGE

CONSUMABLES AND FLOW REQUIREMENTS j

THERMAL REQMTS

ELEC PWR REQMTS

WT/VOL REQMTS

TIME

■

AMT.

PS PWR

AVG PWR

HAS IT-

HABITABILITY

APPLIANCE

CONCEPT

USES/ DAY

TYPE

USED

FLOW

PRESS

TEMP

COOLANT

MT LEAK

. WEIGHT

VOLUME

'31LITY

FUNCTION

CHOSEN

IIP.S/U5E

(*)

-KG/USE-

-MMHG-

-DEG C-

-WATTS-

-KG-

-CU M-

(LD/USE)

{*>

(PSIG)

(DEG F)

(BTII/HR)

(BTU/HR)

-WATTS-

fLRS)

fCIl FT>

~ — - j

EQUIPMENT

SURFACE

DISPOSABLE

15.000

•

39.1

.08

CLEANUP

WIPING

WET/DRY

WIPES

.037

( o.)

( 86.3)

( 2.80)

MANUAL

DISPOSABLE

.000

6.6

.09

COLLECTION

TRASH BAGS

.000

( 0.)

( 14.6)

£ 3.05)

refuse

MANAGEMENT

VACUUM

SKY LAB-TYPE

5.000

0. .

77.

13.8

.02

COLLECTION

ELECTRIC

.082

( 0.)

(262.)

115.0

—

( 30.4)

( J9)

i j
i.j

REFUSE

STORAGE

.787

8.7

.33

DISPOSAL

BIN/CON-
TAINER .

.041

{ 0.)

( 0.)

( 19.2)

(13.28)

GARMENT/

CLOTHES

DISPOSABLE

.000

.0000

.00

158.0

51.7

.61

LINEN

WASH/ DRY

CLOTHES

.000

(.0000)

(.00)

(.0)

( 0.)

{ o.)

(114.0)

(21.50)

MAINTENANCE

CASSETTE

29.2

{ 0.)

( 0.)

. .0

( 64.3)

( 1.49)

•

RECORDER

■

■H

LIBRARY

BOOKS

■Fffl

ENTERTAIN-

( 0.)

{ 0.)

( 1.0)

IKES

*-*

.WENT

TELEVISION

COMMERCIAL

2.000

120.

120.0

■ 22.7

.12

>•
• ’ t—

TYPE

2.000

( 0.)

(409.)

■9

{ 50.0)

( 4.27)

GAMES

CAROS ,

.500

.00

HANDBALL ,

2.000

( 0.)

( o.)

.0 .

( .07)

U-

• i

ETC.

■

| |

•

physical

EXERCISES

EXER GYM,

4.000

’ .6

1 I

CONDITIONING

HAND

1.000

■

{ 0.)

( 0.)

( 1.3)

Hgy

EXERCISER

4.000

■9

.000

( 0.)

■91

( .3)

f h - CABIN AIR (CIRCULATED) .LITERS/SEC (FT 3 /MIN)

2 - CABIN AIR (LOST) , KG/HR (LB/HR)

3 - OXYGEN (LOST) ,KG/HR (LB/HR)

4 - COOLING WATER (CIRCULATED) , KG/MR (LB/HR)

5 - WATER (LOST) , KG/HR (IB/IIR)

6 - NITROGEN

7 - NITROGEN

8 - FREON

9 - WATER

(CIRCULATED) ,KG/HR
(USED) , KG/HR
(CIRCULATED) .KG/HR
(PROCESSED) .KG/HR

(LB/HR)

LB/HItj

(LB/HR)

7 fcou-yn

personal HYGIENE

HA3IT-
A3IUTY
'O’! SYS,

HABITABILITY

FUNCTION

APPLIANCE

FUNCTION

CONCEPT

CHOSEN

USES/DAY

HRS/USE

' ^
UJ

c. r:

C. LU
r_ _ tn
u.

•

FOOD

STORAGE

■REFRIG-

ERATED

SPACE

RADIATOR

.000

,000

FROZEN

SPACE

RADIATOR

.000

FOOD

' ' ".^»A7ICH

WARMING :

HEATING
TP AYS

3.000

2.000

■uv.i;:y

'.I.L/VIUP

DISH

CLEANUP

water spray

WASH/ ELEC.
IIP AT PRY

3.000

2.000

< us

WAS i E
S' 'LL ECU ON

FECAL/

URINE

COL LECTION *

DRY JOHN '
SYSTEM

6.000

.167

'.'•■Ml iUS
LOU i.cno;i

DISPOSABLE

BAGS

.840

.015

CODY

CLEANSING

' ■ '

SHOWER

COLLAPSIBLE

6.000

.250

PARTIAL
BODY
. WASHING

REUSABLE

WIPES

60.000

.037

<■5

PARTIAL
CODY DRYING

REUSABLE

WIPES

60.000

.037

PERSONAL

GROOMING

SHAVING

WINDUP

RAZOR

6.000

.100

HAIRCUTT1NG

RAZOR COMB

VACUUM

COLLECTION

.430

.099

NAIL CARE

MANUAL

CLIPPER

.430

.050

DENTAL

CARE

TOOTHBRUSH

WITH

DENTIFRICE

6.000

.330

i .

it. -

SPACE STATION APPLIANCE CONCEPT FUNCTION MATRIX SUMMARY

CONSUMABLES AND FLOW REQUIREMENTS

THERMAL REQMTS

ELEC PWR REQMTS

WT/VOL REQMTS

AMT.

TYPE USED
{*) -KG/USE-
(LB/L1SE)

PRESS TEMP
-MMHG- -DEG C-
(PSIG) (DEG F)

.0000

.00

4.4

52.

0 .

50.0

(.0000)

( .00)

( .0)

( 40.0)

(179.)

( 0.)

.0000

.00

-23.3

715.

-665.

50.0

(.0000)

( .00)

( .0)

(-10.0)

(2442.)

(2271.)

0 .

295.

( 0 .) ■

(100.7.)

9RO.O

13.6080

.00

247.

371.

167.0

30.0000)

( .00)

( .0)

( .. 0 )

( 842.)

(12GP.)

326.0

.0000

9.44

21.1

0 .

200.

675.0

. 0000 )

(20.00)

( .0)

( 70.0)

( 0 .)

( 683.)

62.0

PK PUR AVG PWR

COOLANT HT LEAK AC AC WEIGHT VOU

-WATTS- -WATTS- DC DC -KG- -CU

(BTU/IIR) fBTN/HR) -WATTS- -WATTS- (IPS) (OI '

136.1 .6

.0 Qqo.nvgg.o

- 5P9.7 2.7

.0 (1300.0) (95. SO)

.0 54.9 .20

>.0 ( 121 ,0; f 7.2 0)

- PI. 5 .6

- ( 179.6) (24.50)

52.0 ( 318.0) (33.70)

.0000) ( .00)1 { .0)

■' 2.7216

( 6 . 0000 )

0 . 0 .

( 0.) ( 0.)

.0 7.0 .0

.0 ( 15.5) ( ,13)

.00

.00)

1292.9

(25.0)

41.1

(106.0)

77.

( 264.)

2P2.

( 997.)

.01

1551.4

105.

278.

.02)

(30.0)

( .0)

{ 360.)

( 948.)

37.

292.

( 125.)

( 997.)

0. 3.

( 0.) ( 11.)

0 . 0 .

( 0.) { 0.)

85.0 — 103. P 1.5

B5,0 ( 22P.7) (55.3

500.0 360.0 Zl.fi .1

,0 .0 ( 47.7M-5.20)

.0 .0 - 75.2 .2

.0 .0 ( 165.6) ( 8.80)

.0 .7

“ ( 1 * 5 ) ( .2

78.5 .2

( 173 . 0 ) ( 9 . 60 )

v~ i_ 7 •

TABLE 2.1-4 SPACE STATION APPLIANCE CONCEPT FUNCTIONAL MATRIX SUMMARY (CONT.)

USAGE

TIME

CONSUMABLES AND FLOW REQUIREMENTS

THERMAL REQMTS

ELEC PWR REQMTS

WT/VOL REQMTS

— — j

HABIT-

ABILITY

‘-.•■asys

<r—
t— »

o .

. 2C.

HABITABILITY

FUNCTION

APPLIANCE

FUNCTION

CONCEPT

CHOSEN

JSES/DAY

IRS/USE

TYPE

(*)

AMT.

USED

-KG/USE-

UB/USE)

FLOW

PRESS

-MMHG-

TEMP
-DEG C-
(DEG F)

COOLANT
-WATTS- ^

HT LEAK
-WATTS-

wji/m).

PK PWR
AC

DC •
-WATTS-

AVG PWR
AC
DC

-WATTS-

WEIGHT
-KG-
f LBS)

VOLUME*
-CU M-

JSLSL,

EQUIPMENT

CLEANUP

SURFACE

WIPING

REUSABLE
WET/ DRY
WIPES

15.000

.037

2.5946
( 5.7200}

.00

(.00)

1551.4
( 30.0)

51.7

(125.0)

105. ■

(360.)

2.7 8. '
{ 948’.)

500.0

360.0

33.3
{ 73.5)

.22
( 7.70)

MANUAL

COLLECTION

DISPOSABLE

BAGS

.000

( 0.)

153.1

(337,6)

* .64

( 22.51)

REFUSE .
KAMA6E-
MEHT

■

•

■

VACUUM

COLLECTION

SKYLAB-TYPE

.ELECTRIC

5.000

.002

■0.

( 0.)

77.

( 252.)

115.0

; .0
.0

13.8
( 30.4)

.02

( .86)

REPOSE

PROCESSING

COMPACTOR

(AIR

PRESSURE)

5.200

.017

.0000

( .0000)

.00

{.00}

1810.0
( 35,0)

21.1
( 70.0)

( 0.)

( P.)

10.0

55.9

(123.2)

.21
{ 7.41)

REFUSE

DISPOSAL

. .

STORAGE BIN/
BIN/CON- .
TAINER

1.000

.032

o. •
( 0.)

“ o:

{ • o.)

44.3
( 97.6)

16.57

(585.00)

GARMENT/

LINEN

MAINTENANCE

CLOTHES
WASH/ DRY

• WATER SPRAY
AGITATION
PLUS ELEC.
DRY

2.000

5.000

49.8950

(110.0000)

.00

(.00)

( .0)

( ,0)

198.

(675.)

1470.

(5020.)

237.0

227.0

239.3

(527.5)

1.31
{ 46.25)

OFF-DUTY ACTIVITIES

ENTER-

TAINMENT

MUSIC

■

CASSETTE

RECORDER

3.000

2.000

( o.)

J 30. :

(102.)

30.0

66.4

(146.4)

.08
{ 2,98)

LIBRARY

BOOKS

3-000

2.000

( 0.)

6.3
( 13.8)

.00)
( .50)

TLLEVISION

COMMERCIAL

TYPE

3.000

2.000

( 0.)

120.

( 409.)

120.0

22.7
< 50.0)

.12
( 4.27)

GAMES

HANDBALL

.500

2.000

( 0.)

0. ,
( o.)

. *0
.0

( .8)

.00
( .07)

DARTBOARD/

DARTS

.500

2.000

( 0.)

( 1.8)

.00
{ .04)

BINOCULARS

.500

2.000

( 0.)

S 4

{ 12^0)

.00
( .17)

CARDS

.500

2.000

( 0.)

0 .

( 0.)

3.0
( 6.7)

.00
( .17)

CALCULATOR

.500

2.000

0 .

( 0.)

3.0

( 6.6)

.00
( .13)

7 /C. 211,-7(1

TABLE 2.1-4 SPACE STATION APPLIANCE CONCEPT FUNCTIONAL MATRIX SUMMARY (CONT.)

USAGE

...TIME

CONSUMABLES AND FLOW REQUIREMENTS

THERMAL REQMTS

ELEC PWR REQMTS

WT/VOL REQMTS

HABIT-
ABILITY
c- "•.*?

(■'ABIT ABILITY
FUNCTION

APPLIANCE

FUNCTION

CONCEPT

CHOSEN

USES/ DAY
HRS/USE

TYPE

(*>

. AMT.
USED

-KG/USG-

(LB/USE)

FLOW

. (*)

PRESS

-MMHG-

(PSIG)

TEMP
-DEG C-
(DEG F)

COOLANT
-WATTS -
(BTU/HR)

HT LEAK
-WATTS-
( BTU/HR)

PK PUR
AC
DC

-WATTS-

AVG PWR
AC
DC

-WATTS-

WEIGHT

-KG-

(LBS)

VOLUME
-CU M-
(CU FT)

r- lu ■

*-»

. . r ■

t~. —»

t 1

it.. h-

c- O

PHYSICAL

CONDITION-

ING

EXERCISERS

EXER-GYM

HAND EXER-
CISER

6,000

1.000

6.000

.000

•

• ■

( 0.)
0.

( 0.)

{ 0.)
0.

( o.)

. .0
.0

( 2.G)
.2

{ *5)

.01

( .36)

.00

( .04)

f "

.(*)

1 - CABIN AIR (CIRCULATED) .LITERS/SEC (FT J /MIN)

2 - CABIN AIR (LOST) »KG/HR (LB/HR)

3 - OXYGEN (LOST) , KG/HR (LB/HR)

4 - COOLING HATER (CIRCULATED), KG/HR (LB/HR)

5 - HATER (LOST) , KG/HR (LB/HR)

6 - NITROGEN (CIRCULATED), KG/HR (LB/HR)

7 - NITROGEN (USED) , KG/HR (LB/HR)

8 - FREON (CIRCULATED), KG/HR (LB/HR)

•!) - HATER (PROCESSED) , KG/HR (LB/HR)

D2-118572

SS“Z

2. 1.3. 4 (Continued)

REFRIGERATED STORAGE - SPACE RADIATOR

The refrigerator/ freezer is simply an insulated food storage box, with coolant from the
spacecraft ECS radiators routed through tubing within the refrigerator walls. This
concept was used for the Skylab refrigerator. The Shuttle refrigerator was sized pro-
portional to the above Skylab data based on the refrigerator food capacity. The wall
insulation was 10.16 cm {d.Q in) thick. It was assumed that the radiator coolant would
be of sufficiently low temperature for this concept to be feasible.

FOOD WARHIKG - HEATIHG TRAYS (SKYLAB)

The heating trays consist of an insulated food tray with three heating cavities
surrounded by imbedded electrical resistance heating elements. This concept was used
on Skylab, and the actual Skylab weight/volume/power data were used for the study. A
heating time of 1 1/2 to 2 hours Is required to warm the food. Two hours was used for
computing thermal penalties to the cabin cooling circuit. Each Skylab heating tray
weighed 10.9 kg (2 A lb).

DISH CLEflmJP - REUSABLE DISHES ARP UTENSILS WITH DISPOSABLE WET/CRY WIPES

The reusable dishes and utensils were assumed to be metallic dishes and utensils. Ho
food packaging penalty was used for this system. Two wet wipes and one dry wipe were
assumed used to clean the dishes per man.

D2-IIS572

2. 1.3.4 (Continued)

ifECAL/URlKE COLLECT 10>i/TRAf!Sf ER - DRY JOHN

jThe dry jobn commode assembly serves as a waste collector and feces/urine storage/
(processing unit. The seat is similar to the terrestrial type with modifications
necessary for zero-gravity usage. The feces are transferred to the storage/processing
section (collector) via the fecal transfer duct. The fecal transfer duct contains
provisions for entrainment airflow for separating and moving the stool from the anus to ■
the collector. Air positioning jets shown on the schematic are used to assist the user
in positioning properly on the seat. This portion of the system was not considered
part of the appliance, since recent tests have shown the jots are not necessary. The
interface between the transfer duct and the feces collector is the collector valve. The
valve is manually actuated and seals the collector after use to permit vacuum drying
of the feces. A slinger is incorporu ; to maximize the feces and wipes area exposed
to vacuum by depositing the feces and wi r es on the wall of the collector. Entrainment
air and air removed by the vacuum pump are passed through filters and returned to the
cabin. A vacuum pump was assumed to satisfy the vehicle requirement of no venting
external to the spacecraft.

VOfliTiiS COLLECT IQN/TRANSFER - PORTABLE DISPOSABLE COLLECTOR (AIRLINE TYPE)

The portable disposable collector is a light flexible bag with a drawstring closure
device. The bag is used on all airlines and is made of thin gage plastic. The crewman
can store the bag in a clothes pocket where It will be ready for use at any time. The
bag is unfolded and grasped near the opening by both hands and held against the face
enclosing the nose and mouth. Proper placement of the bag against the face provides the
seal. The bag Is sealed after use by tying a knot fn the closure cord and discarding
the bag and contents into the feces collector.

PARTIAL CODY WASHING - DISPOSABLE HIRES (SKYLAB)

The disposable wipes are made up of prepackaged wipes which were used on Skylab, The
wipes are contained within a package to eliminate water evaporation during storage.

The units arc used and discarded.

PARTIAL BODY DRYING - DISPOSABLE DRY WIPES

The disposable dry wipe consists of wipes made of 4 ply "wet strength" pafeer. The
paper wipes are 12 X 18 indies and are discarded after two uses. The wipe usage is
based on 10 times per day per man. The wipes are disposed of by depositing into a
vacuum drier to remove excess water. The dried wipe is then deposited Into the refuse
system. The weight and volume of the wipe dispenser was Included as part of the
appliance.

SHAVING - DRY SKAVE-UIIIOUP RAZOR ( SKYLAB)

The windup razor dry shaver consists of a mechanical windup motor shaver with a hair
particle reservoir. The unit was used on Skylab and the weight and volume used were
the same as the flight weight unit.

TEETH URllSHiriG - TOOTHBRUSH VilTH DENTIFRICE

The toothbrush with dentifrice consists of a terrestrial type toothbrush with dentifrice.
Tlie dentifrice is digestible to be nonhnzardous if accidentally swallowed and is dispensed
by a roll-up tube. Mouthwash is also provided in a soft plastic "squeeze bottle," One
squeeze bottle per each crewman Is provided for hygiene reasons. The mouthwash is used
to mix with the dentifrice and is expectorated into a sink or fecal collector. This
appliance has flown on ApDllo

D2-118572

2. 1.3.4 (Continued)

►a 2

HOUSEKEEPING

REFUSE

DISPOSAL

SURFACE

WIPING

DISPOSABLE
CLOTHES ,

f VACUUM TRASH
U COLLECTION

SURFACE WIPING - DISPOSABLE HET/TOV WIPES (PREPACKAGED)

The disposable wetydry wipes consist of prepackaged wet wipes which were used on Sky lab.
The wet wipes are contained within a package to eliminate water evaporation during
storage. The dry wipes are dispensed from a 196 count container. The wet and dry wipes
are used for cleanup and discarded.

MANUAL COLLECTION - WASTE/TRASH BAGS

aThe waste/trash bags employ trash bags and disposable bags for refuse collection. This
jape! lance uses the bag concept used on Skylob. The trash containers are mounted on the
[back side of collector doors. The collector areas are located in the food management,
[personal hygiene, and other areas where significant amount of bulk refuse 1$ generated,
i The study assumed 3 collectors for Shuttle. Trash entry Into the bag is through the
[front of the collection door through a slit In the bag. The refuse collection was
[based an Its uncompressed volume. Disposable bags were applied for uncompresslble
itrosh. The disposable bags are held during use by snaps located at various locations
j throughout the vehicle. Both types of bags have bag closure devices to seal the bag
(after filling.

1 VACUUM COLLECTION - PORTABLE VACUUM/ELECTRIC {SKY LAB)

The portable vacuum/electrlc is identical to Use vacuum used on Skylab. The vacuum
has a hose and pickup attachments to assist In vacuum pickup. The unit has a strap
and handle for carrying/using the unit. Vacuum cleaner bags were assumed to require
changing once per week (.142 cycles per day).

REFUSE DISPOSAL - STORAGE DIII/CONTAINER

The storage bln/contatner employs a locker to store the refuse. Sterllant capsules
wore assumed for retarding the bacterial growth. The refuse was assumed to be collected
by bags (Skylab, or equivalent) and transferred to the storage locker. A concept
provides a sterllant capsule for each bag of refuse stored In the locker. The capsules
usnd for the study were 2.25 grams each with a volume of .33 cubic inches. The walls
of the storage locker were assumed to be aluminum. Sizing of the locker was based on *
the refuse volume including the storage bags.

GJMKEHT/LIHEN - DISPOSABLE CLOTHES

No clothes washer/dryer is used, and soiled clothing are simply disposed of and replaced
; by new ones. An average wear rate of .484 kg (I.OfiG lb) clothlng/towels/washcloths
i was used per man per day. A packaging weight factor of 1.3 was applied to the disposable

I D..1 I. - C >,1 2 .... J L.

2. 1.3.4 (Continued)

I t VSBBES * ~ , ■«. fl t ejjaSCGB I CBiSBgg 1 MW t aflHM fl MaWW Wfc ii np 8B31 OH8 B W8W Ml BBBMHBBBM— — — ,

MUSIC - CASSETTE PLAYER/ RECOVER

The cassette player/recorder includes the following equipment: (1) tape player/recorder,
jz) headsets, {3) microphone kit, (A) power cord/ converter, (5) batteries, (6) cassette
kit, and (7) wardroom speakers. The tape player can be used on conventional batteries
or via a converter from 28 VDC to 6 VDC on spacecraft power. The tape recorder plays
cassettes and is provided with a speaker and an adaption to headsets for private use.
s LIBRARY - BOOKS

3 Hooks consist of individually selected off-the-shelf paperback books taken on the mission.
iThe books are stored and when in use are provided with a cover for nonfl amiability. The
|j covers are fabricated from Beta cloth.

I VISUAL RECREATION - TELEVISION

ItIio television provides programed television programs to the crewmen. The data presented
fiwere based on 15-inch Panasonic. The Sony is-also very similar to this model. The unit
jdoes not provide the means for use of video tape.

j GAMES - HMBBALL/CARDS

IThe handball appliance provides three hand balls, one pyrell, one sponge, and one rubber
hand ball. The balls are covered with a nonflartmablo Fluorel covering. One commercial
jball is coated with Fluorel, The pyrell NERF ball was dipped In ainnqnium-dehydrogen
| phosphate and coated with Fluorel. The third ball is a toy ball coated with Fluorel. The
1 balls are packaged in a sponge rubber container.

| The card gar 1 * provides card decks and card deck retainers for card playing in zero-g.

1 The card retainer is constructed using a flexible strap with a magnet at each end. The
j assembly is covered with Beta cloth. The cards are standard cards manufactured using a
[lamination of three layers of Scheufelin paper E-20. Each deck Is stored In an aluminum
[container for nonflanuiability. Four decks of cards were assumed for Shuttle-

EXERCISERS - EXER-GYM/HAHD EXERCISER

IThe exer-gym is a conmerclal grade manufactured by Exer-Genie. The unit provides exorcise
j by means of varying rope tension to produce the desired push/pull restraint forces. Exer-
jgym works by putting each foot in the strap loops and pulling rope with one or two hands.

I A storage container is provided for the exer-gym. The study assumed four exer-gyms were
j provided for Shuttle.

iThe hand exerciser Is provided to keep hand and arm muscle condition. The hand exercisers
1 are shaped to fit the hand and are used as a '‘squeeze" type exerciser for maintaining grip
I strength. The units are coated with Fluorel for nonflammability. The study assumed four
[hand exercisers were provided for Shuttle,

D2-11E572

D2 : I18572

2,1.3, 5 Selected Space Station Appliance Concepts

■4

The appliance system selected for the Shuttle Qrbiter is described in the
following paragraph. A summary of thermodynamic, electrical power, weight
volume, and consumables and flow requirements for each of these selected
appliances is contained in Table 2.1-4.

2-40

2. 1.3. 5 {Continued)

I REFRIGERATED/FREEZER STORAGE - SPACE RADIATOR

The refrigerator/freezer Is simply an insulated food storage box, with coolant from the
spacecraft ECS radiators routed through tubing within the refrigerator walls. This concept
was used for the Skylab refrigerator. The Space Station refrigerators/freezers were sized
proportional to the Skylab data based on the refrigerator/freezer food capacity. The wall
insulation was 10.16 cm (4.Q inch) thick. It was assumed that the radiator coolant would
be of sufficiently low temperature for this concept to be feasible.

FOOD HARMING - HEATING TRAYS (SKYLAG)

The heating trays consist of an insulated food tray with three heating cavities surrounded
by Imbedded electrical resistance heating elements. This concept was used on Skylab, and
the actual Skylab welght/volume/power data were used for this study. A heating time of
1 1/2 to 2 hours is required to warm the food. Two hours was used for computing thermal
penalties to the cabin cooling circuit. Each Skylab heating tray weighed 10.9 kg (24 lb},

DlSHWASHER/EftYER COMBINATION - HOT HATER SPRAT WASH-FORCED HOT AIR ELECTRIC HEAT DRY

Dish washing Is accomplished by spraying hot water (with an 0 psig pump head) over the
dishes in a slowly rotating drum. Drying Is actcmoli shed by a circulating flow of air over
the dishes which is heated by an electrical heating element. The heater also heats the
dishes by radiation. Heater size was based on a 1 hour drying time.

FECAL/UIUHE COLLfCT?OrJ/TRAHSfER - DRY JOHH

The dry john comnode assembly serves as a waste collector and feces/urine storage/processlng
unit. The seat is similar to the terrestrial type with modifications necessary for zero-
gravity usage. The feces are transferred to the storage/processing section (collector)
via the fecal transfer duct. The fecal transfer duct contains provisions for entrainment
airflow for separating and moving the stool from the anus to the collector. Air positioning
jets shown on the schematic are used to asstsi the user in positioning properly on the seat.
This portior of the system was not considered part of the appliance, since recent tests
have shown the jets are not necessary. The interface between the transfer duct and the
feces collector is the collector valve. The valve is manually octuated and seals the
collector after use to permit vacuum drying of the feces. A slingpr Is incorporated to
maximize the feces and wipes area exposed to vacuum by depositing the feces anti wipes on
the wall of the collector. Entrainment air and air removed by the vacuum- pusp are passed
through filters and returned to the cabin, A vacuum pump was assumed to satisfy the vehicle
requirement of no venting xternnl to the spacecraft.

VOHITUS COLLECT jOil/TIWisrf A - PORTABLE DISPOSABLE COLLECTOR (AIRLUiE TYPE)

The portable disposable collector is a light flexible bog with a drawstring closure device.
The bag is used on all airlines and is made of thin gage plastic. The crewman can store
the bag in a clothes pocket where It will be ready Tor use at any time. The bag is unfolded
and grasped near the opening by both hands and held against the face enclosing the nose and
mouth. Proper placement of the bag against the face provides the seal. The bag is sealed
after use by tying a knot in the closure cord and discarding the bag and contents into the
feces collector.

WOLE CPPy 5H0HER - C0LLAP51BLE (SKY LAB)

The collapsible shower was used an Skylab. The shower stall is folded down for use to
minimize space. The shower enclosure consists of two end ring closures and a translucent
beta cloth skirt with stiffening rings. Ore end ring attaches to the floor and the other
to the ceiling when the shower is in use. Water Is delivered through a nozzle with vacuum
pickup of water. The waste water is centrifugally separated and routed to the water waste
management system. Six pounds of water were assumed per shower. One towel per crewman
per shower is used for drying.

PARTIAL BODY WASHING - REUSABLE WET WIPES

The reusable wet wipe appliance is a sponge bath technique used to clean local areas of
the body. A wetting and soaping unit, with hand holes is supplied for the function. The
unit has a water supply outlet, a storage area for soap and a fan for providing water
entrainment during use. A centrifugal separator Is provided upstream of the blower to
collect used water. Water temperature is controlled by mixing hot with cold water in a i

temperature controlled mixing valve. The crewman first “soaps up" the wipe in the wetting
unit, then uses it to clean the required areas of the body. The wipe is wrung out and
rinsed inside the wetting unit. The rinsed damp wipe is used to wipe excess soar from the
body. A final rinse and wringing out of the wipe is accomplished and reused. Reusable
wipes are provided on a per man basis. The wipe Is washed and dried using a washing machine
and dryer. After 60 washings, the wipe is discarded and replaced. The reusable -wipes are
10 inches square of 4 ply "wet strength" paper.

PARTIAL 00DY DRYING - REUSABLE PUT WIPES

The reusable dry wipe appliance consists of wipes made of terrycloth. The terrycloth wipes
are 15 X 30 inches and are used 10 times per day hefore washing. The concept Includes the
weight and volume of the wipe dispenser. The towels are washed and dried after one day of
usage and are discarded after 60 washings. The concept is penalized for the washcr/drycr
function required to recycle the wipes. The terrycloth wipes are smaller and lighter than
the terry towels used for whole body drying after showering.

*■

2. 1.3. 5 (Continued)

The concept requires two men to operate which Is a disadvantage from the crew time
The unit used for vacuum collection is the power module used on Skylab.

SHAVING - DRY SHAVC-H1HUUP RAZOR tSKVLAB)

| The windup razor dry shaver consists of a mechanical windup motor shaver with a hair
particle reservoir. The unit was used on Skylab and the weight and volume used were the
same ns the flight weight unit.

MAIN TUTTING - RAZOR- COMB/ VACUUM' COLLECTION

Hie comb/vacuum collection unit consists of a razor comb with a hand-held vacuum pickup
'device,
aspect.

HAIL CARE - MANUAL HAIL CLIPFEN/BAG COLLECTION

The manual nail clipper/bag collection unit consists of a terrestrial type nail clipper
enclosed by a bag to contain nail clippings, the bag incorporates a finger cuff and ring
to form a seal around the finger during nail cutting. The collection bag Is transparent
to observe nail clipping.

TEETH CRUSHING - TOOTHBRUSH WITH DENTIFRICE

The toothbrush with dentifrice consists of a terrestrial type toothbrush with dentifrice.
The dentifrice is digestible to be nonhazardous if accidentally swallowed and Is dispensed

1 . by a roll-up tube. Houthwash Is also provided in a soft plastic "squeeze bottle." One
■squeeze bottle per each crewman is provided for hygiene reasons. The mouthwash is used
j to mi x with the dentifrice and is expectorated into a sink or fecal collector. This
[appliance has flown on Apollo.

ti'itWZQ

/ •- >

V. *

2. 1.3. 5 (Continued)

I SURFACE WIPING - REUSABLE WET/ DRY HIPES

The reusable wet/dry wipes are used for equipment cleaning and drying. Terrycloth
reusable dry/wet wipes are used a maximum of 5 times before washing. A wetting unit with
hand holes is supplied for the function. The wetting unit has a water supply outlet
and a fan fqr providing water entrainment during use. A centrifugal separator is provided
upstream of the blower to celled usTjd water. Water temperature is controlled by mixing
hot with cold water in a temperature controlled mixing valve. The crewman wets the wipe,
uses it for area cleanup (disinfectant soap is located at the wetting unit) and can be
rewetted if necessary for cleanup. The wipe Is wrung opt in the wetting unit and is
washed and dried after one day of usage and is discarded after 60 washings. The dry wipes
are provisioned 3 per day for a maximum of 15 cleanup functions. The concept is penalized

for the usage of a washer/dryer for recycling the cleaning and drying cloths.

MANUAL COLLECTION - HASTE/ TRASH BAGS

The waste/trash bags employ trash bags and disposable bags for refuse collection. This
appliance uses the bag concept used on Skylab. The trash containers are mounted On the back
side of collector doors. The collector areas are located in the food management, personal
hygiene, and other areas where significant amount of bulk refuse is generated. The study
assumed 15 collectors for Space Station. Trash entry Into the bag Is through the front of

the collection door through a slit in the bag. The refuse collection was based on its

uncompressed volume. Disposable bags were applied for uncompressible trash. The disposable
\ bags are held during use by snaps located at various locations throughout the vehicle. Both
\ types of bags have bag closure devices to seal the bag after filling.

| VACUUM COLLECTION - PORTABLE VACUUM/ ELECTRIC (SKYLAB)

iThe portable vacuum/electric is identical to the vacuum used on Skylab. The vacuun has
“ a hose and pickup attachments to assist in vacuicn pickup. The unit has a strop and handle
for carrying/using the unit. Vacuum cleaner bags were assumed to require changing once
per week (.142 cycles per day).

REFUSE PROCESSING - COUP ACTOR- AIR PRESSURE

The air pressure compactor uses air pressure against a piston for refuse compaction. The
compactor Is used for dry and moist compactlble refuse. The unit provides a sterilant to
the waste to prevent bacterial growth. The refuse is placed into a waste storage bag in
the compactor. The compactor is actuated and compression of the refuse is accomplished
using cabin air pressure of 40 psi. The piston used for the study was 9 inches square
which results in 4000# of compaction pressure. The uncompressed refuse volume per day
2.45 FT^/day for Space Station was divided by the compactor volume of .47FT’ to determine
the uses per day. Prior to tying the waste storage bag liner a sterilant capsule is placed
into the bag. After tying, the capsule Is broken releasing the sterilant gas.

REFUSE DISPOSAL - STORAGE BIN/C0NTA1HER

The storage bin/container employs a locker to store the refuse. Sterilant capsules were
assumed for retarding the bacterial growth. The refuse was assumed to be collected by
bags (Skylab, or equivalent) and transferred to the storage locker. A concept provides
a sterilant capsule for each bag of refuse stored in the locker. The capsules used for
the study were 2.25 grams each with a volume of .33 cubic inches. The walls of the storage
locker were assumed to be aluminum. Sizing of the locker was based on the refuse volume
including the storage bags.

GARMFhT/LINEK - HATER SPRAY AGITATION/FORCE HOT AIR-ELECTRIC HEAT

The clothes washer cleans using a high velocity Jot of water which is sprayed into a wire
mesl^ drum from the outer circumference. The drum is slo'./’y rotated to allow continuous
removal of the water. A high speed spin cycle is used to remove the excess water after
washing and rinsing. Clothes drying is accomplished using a Jot of air spray at 60°C
(140 o Fj which is directed into the clothes from outside the drum. The clothes are contained
in a wire mesh drum which is rotated slowly in a direction counter to the air inlet. A
prototype clothes dryer has been constructed utilizing this concept.

D2-1I8572

vv-z

j MUSIC - CASSETTE PUOTR/RECORDER

I The cassette player/recorder concept includes the following equipment: (1) tape player/;^

recorder, {2) headsets, (3) microphone kit, (A) power cord/qonverter, (5) batteries,

(6) cassette kit, and {/) wardroom speakers. The tape player cart be used on conventional*'
batteries or via a converter from 28 VQC to 6 VDC on spacecraft power. The tape recorder
I plays cassettes and is provided vrith a speaker and an adaption to headsets for private use.

[ IIBRART - BOOKS

[Stocks consist of individually selected off-the-shelf paperback books taken on the mission.

I The books are stored and when in use are provided with a cover for nonflammability. The
.covers are fabricated from Beta cloth.

J VISUAL RECREATION - TELEVISION

I The television provides programmed television programs to the crewmen. The dat*a presented
were based on 15-inch Panasonic. The Sony is also very similar to this model. The unit
does not provide the means for use of. video tape.

•j GAMES - HAN ‘BALL/DART BOARP/DnRTS/CABDS/OlHOClJLAR. KIT/ CALCULATOR

BThe handball appliance provides three hand balls, one pyrell, one sponge, and one rubber
in hand ball. The balls are covered with a nonflammable Flucrel covering. One comercial
ybalT Is coated with Fluorel. The pyrell NERF ball was dipped In ammonlim-dehydrogen
S phosphate and coated with Fluorel. The third ball Is a, toy ball coated with Fluorel. The
H balls are packaged in a sponge rubber container.

g The dart board appliance utilizes darts and board with velcro for a zero-g dart game.

0 Twelve darts were provided with the heads covered with velcro hooks and attach to the board

1 by means of velcro plle/hook attachment system. A dart holder container was provided as
m part of the concept. The system did not work well on Skylab {darti were not stable), so
H redesign of this system would be required prior to flight.

H The card game provides card decks and card deck retainers for card playing In zero-g.
a The card retainer Is constructed using a flexible strap with a magnet at each end. The
I assembly Is covered with Beta cloth. The cards are standard cards manufactured using a
H lamination of three layers of Schcufelin paper E-20. Each deck is stored in an aluminum j

I container for nonflammability. Eight decks of cards were assumed for Space Station, {

The binocular kit provides binoculars for viewing distant objects such as earth and
satellites. The binoculars are "trlnovid" 10 X AO, manufactured by E. leitz, Inc. Velcro
attachment strips are provided for attachment when used in specified areas.

The calculator appliance provides a Hewlett-Packard HP-55 programmable pocket calculator.

! e calculator is an electronic slide rule with programmable tapes for special programs.
The study assumed six units were supplied for 5pace Station.

EXERCISERS - EXER-GVM/HAKD EXERCISER

The exor-gym Is a cotmerclal grade manufactured by Exer-Genie. The unit provides exercise
by means of varying rope tension to produce the desired push/pull restraint forces. Exer-
gym works by putting each foot In the strap loops and pulling rope with one or two hands.

A storage container Is provided for the exer-gym. The study assumed six exer-gyms were
provided for Space Station.

The hand exerciser is provided to keep hand and arm muscle condition. The hand exercisers
are shaped to fit the hand and are used as a "squeeze" type exerciser for maintaining grip
strength. The units are coated with Fluorel for nonflamnabllity. The study assumed six
hand exercisers were provided for Space Station.

ZL93 tt'ZQ

P2-1I8572

... j

2.1.4 Shuttle Freezer Conceptual Design

Crew Systems Division was requested by the Life Sciences Directorate to
determine the feasibility of a freezer for the frozen storage of whole
food items as well as medical samples which would not be permanently
mounted, but which could be readily installed on board the Shuttle for
selected orbital missions* The development of the freezer conceptual
design, which is described in detail in Reference 3, is summarized in
this section.

Primary design requirements of the freezer are that it be a portable
appliance which can be easily installed and removed, that it provide
storage capacity and restraint for a designated amount of food and medical
samples, and that the storage space be maintained at a particular thermal
environment. The design must be such that it has a minimum of interface
requirements with Shuttle systems and require- no. penetration of the
Orbiter cabin pressure wall. . Food and medical, samples must be stored to
provide isolation from one another. ■ And -the freezer must operate in the
environment of the Orbiter crew compartment; -The design mission duration
is 30 days, and the number of crew members is seven (7),

Frozen foods to be stored in the freezer are common foods such as meats,
vegetables, fruits, and ice cream which will augment the normal Shuttle
crewman's diet of rehydrated foods. The food volume and weight require-
ment is derived from an average of two (2) frozen servings per day per
crewman for an entire 30-day mission (a total of 420 servings). Each
serving will have a packaged dimension of 4“ x 4" x 1". The total launch
food weight and volume requirements derived from these specifications is
215 pounds and four (4.0) cubic feet, respectively,

■Food will be held at -40°F prelaunch and stowed in the freezer initially
at this temperature. The freezer will maintain food items at an average
temperature of from 0°F to -20°F.

O..AC

D2-118572

t.lA (Continued)

Samples of each crewmember's urine and feces are to be collected during
the entire Orbiter mission duration and stored in the freezer for return
to earth. Urine samples are collected continuously from all crewmen and
placed into the freezer once a day. Feces sample are to be placed into
the freezer as they are collected. Total medical sample weight and volume
stored in the freezer during a 30-day mission are 128.3 pounds and 2.63
cubic feet, respectively.

2.1. 4.1 Freezer Volume Optimization

Because of the critical space limitations of the Orbiter crew compartment
and the shape constraints created by the Orbiter side hatch opening and
potential mountirg configurations, an optimization effort was conducted to
provide a freezer envelope which would make the most efficient use of the
space available. This optimization was accomplished by first determining
the most efficient freezer compartmentation arrangement and then defining
the envelope within which the freezer must be designed. The storage volume
was divided into four individual compartments with volumes' of .06, 1.00,

1.40, and 1.60 cubic feet.

The fill and empty sequence begins with the 0.6 ft empty volume being

filled with medical samples as the smallest food storage volume (1.0 ft )

’s being emptied. These volumes are sized such that a food storage volume
is completely empty as the sample volume is completely full; then medical
samples are placed into the empty food storage volume. This sequencing is
continued during the duration of the mission with the remaining three food
storage volumes.

,2.1.4. 2 Freezer Envelope Definition

Two dimensional constraints were considered in defining the freezer envelope:
(1) the crew equipment storage module dimensions and (2) the side hatch
opening. Equipment storage modules have standard external dimensions and

2-46

2. 1*4. 2 (Continued)

mounting fixtures and are to be mounted in arrays on both the forward and
aft bulkhead of the Orbiter crew compartment. Location and arrangement of
the modules are illustrated in Figures 2.1-9(a) and 2.1-9(b). The modules
are mounted on posts, which extend from the Orbiter floor to ceiling, using
fasteners located at each corner of each module. As seen in Figure 2.1~9(b),
when in place the storage modules form the forward bulkhead of the crew
compartment. Each module is independently mounted and can be individually
removed; however, if a module is omitted, a close out panel must be in-
stalled to insure the composite strength of the entire storage module
system. Modules are independently supported (do not rely on the floor or
other modules) and are separated from adjacent modules by 3/8 inch on all

sides.

■

The volume which can be passed through the Orbiter side hatch is defined
by a 25" x 25" x 50" rectangular volume. This limited the freezer dimensions
to the equivalent volume of four storage modules.

2. 1.4. 3 Freezer Refrigeration System Description

The freezer refrigeration system includes the storage volume to refrigeration
unit (R/U) heat transmission system and the refrigeration unit. Since the
onboard Orbiter liquid cooling temperatures are not low enough to provide
the desired storage temperature, the refrigeration system must therefore
utilize a mechanical refrigeration device. Several options are available
to transfer the heat gained in the storage volume to the refrigeration unit
(R/U). These options can be divided into three basic types: (1) circulating

cooling medium, (2) circulating refrigerant and (3) directly connected R/U.
These types are illustrated schematically in Figure 2.1-10 with two identified
.options (A and B) for each type.

Of the six types of heat transmission presented, type IB is eliminated
because of higher volume requirement necessary for the three individual
connective systems (fans and finned heat exchangers) and the inherent higher

D2-1IS572

1 I .- ■/ . I J 1 I \

P2-1I8572

211.4.3 (Continued)

electrical power consumption and weight. Both options In type II are
eliminated due to the potential safety hazard presented in circulating the
R/U refrigerant outside the sealed volume of the R/U. And the type I I IB
is eliminated since it violates the requirement for isolation of medical
samples from food. Therefore, types IB and IIIA are the systems best
suited for storage volume to R/U heat transmission.

2. 1.4. 4 Refrigeration System Trade Study

A screening of potential R/U concepts was conducted by LTV Aerospace to
identify those concepts which were applicable to the requirements of the
Shuttle freezer performance. Refrigeration concepts considered by LTV and
a critique of each is tabulated in Table 2.1-5. Of these concepts, three
were chosen for continued evaluation:

o Thermoelectric
o Stirling Cycle

o Vapor Cycle •

The working gases for the Stirling cycle and the vapor cycle are helium
and ammonia, respectively.

A performance description, which covered the operating range required by
the Shuttle freezer, was derived for each of these concepts using three R/U
heat sink approaches: (1) cabin air at 80°F, (2) water cooling at 80°F,

and (3) water cooling at 45°F. Preliminary estimates of the thermal leakage
and thermal perturbation rates were made to determine the peak and average
cooling rates to be developed by the R/U. Using these values the thermal
loads weight and electrical power requirements of the three R/U types were
derived for each mode of cooling.

2-50

TS-Z

*-■ *

/ .'***■; v

TABLE 2,1-5. REFRIGERATION UNIT CANDIDATES

REFRIGERATOR

MISSION

suitability

HARDWARE

DEVELOPMENT

STATUS

FIXED

ELEMENTS .

COP*

SAFETY

PROBLEMS

C05TS

COMMENTS

WEIGHT

VOLUME

DEVELOPMENT

RECURRING

*—

tu £

w M*
< > s*,

Ju =

STIRLING

•

OCDO

SOUS UNITS AVAIL*
ABLE SUITABLE for
ZERDOUSE

GOOD
. ■

GOOD

home

PAIR

MORE
EXPENSIVE
THAN VAPOR
COVPRESSION

DEVELOPMENT IS NEEDED BUT COSTS SHOULD BE
REASONABLE

v,,.

QUESTIONABLE

BOVt UNITS AVAIL-
ABLE SUITABLE FOR

.ZERO O' use.

GOOD

FAIR

NONE

FAIR

MORE
EXPENSIVE
Than VAPOR
COMPRESSION

CONSIDER ONLY IF VERY LONG LIFE AND LOiV POWER
CONSUMPTION ARE NEEDED

3RAYT0N

NOT A

VIABLE

CANDIDATE

LOW COP AND NEEDS DEVELOPMENT FOR THIS TEMPERATURE

VAf£}«

■Cvcitw-cr.

n?P<iiO£PATOnS

•

GOOD

• NO DEVELOPMENT OF
APPROPRIATE SIZE

: EQUIPMENT FOR
ZEBOD

• SX'STING HARDWARE
VL'Ci* too LARGE or
IS NOT SUITABLE

GOOD

VERY

GOOD

FLUIDS

FOR

CYCLE

EXPENSIVE

THAN

STIRLING

EXPENSIVE

THAN

T/E

• NEEDS DEVELOPMENT OF A ZERO G COMPRESSOR

• MAYBE ABLE TO MODIFY A STIRLING MACHINE

A^SCRPTOVT

acfo^rtion

R.E e R-G£RAT0R5

NOT A

VIABLE

CANDIDATE

■

SEVERAL FACTORS MAKE THIS CHOICE UNCOMPETITIVE

ThErwOf lECTSICS

it/ei

GOOD

PRODUCTION UNITS
. AVAILABLE FOR
SPACECRAFT USE

EXCELLENT

POOR

NONE

EXCELLENT

COP MAY REOU1RE EXCESSIVE POWER ATTHIS LOAD AND
TEMPERATURE

£XPe?JDA0tE5

NOT A

VIABLE

CANDIDATE

■

PENALTY FOR CONSUMABLES tSTOO HIGH FOR ONE YEAR
nESUPPLY

OtRECTfONAL

S S ACE

RAOJATORS

QUESTIONABLE
SUITABLE for
On ORBIT
VW3N PHASE
ONLY

SPACE QUALI FI EO

POOR

- •

EXCELLENT

MINOR

•,

fair

FAIR

* SYSTEM SUFFERS FROM highly COMPLEX INTERFACES
■ QUESTIONABLE FEASIBILITY

WITHOUT ORIENTATION CONSTRAINTS

Prepared by LTV Aerospace

D2-11F572

p2-Il£572

2 , 1.4. 4 (Continued)

The combination of three R/U concepts and three heat sink options provided
nine (9) individual R/U systems which could be traded. The engineering data
along with the more intangible characteristics such as reliability, safety,
and maintenance factors were used as inputs to a computerized trade program
developed for the Crew Appliance Concepts study (Reference 1).

The results of freezer concept trade are tabulated in Table 2.1-6. Briefly,
the table illustrates (from left to right) each weighing factor (or
criteria) being evaluated and the minimum and maximum of the nine values
investigated with an arbitrary maximum number of points (RTS) assigned to
each factor. The number of points awarded for each of the nine concepts
is tabulated in columns labeled 1 through 9. The curve for determining the
points awarded is a straight line of value (lbs. ft , watts, etc.) versus
points having a negative or positive slope depending upon the contribution
of the factor to the Shuttle performance. For example, weight is a negative
factor, therefore the point assignment line will be negative; whereas,
reliability is a positive asset and the line will be positive.

The total points listed reflect the summation of those points determined
for each factor for each concept. The maximum number possible is 85.

The final rating shown on the last line is the ratio of the point summation
to the maximum possible points (85) shown in percent. The Stirling cycle
system utilizing 45°F water cooling provides the highest rated concept.
However, because of a location restriction which could be imposed on a
water cooled system, NASA directed that preliminary design studies of the
freezer be conducted using a cabin air cooled system. Of the air cooled
concepts the Stirling cycle rated highest. It was therefore decided to
-proceed with a freezer preliminary design utilizing the air cooled, Stirling
cycle concept to satisfy the R/U function.

2-52

• TABLE 2.1-6, CREW APPLIANCE SELECTION MATRIX FOR FREEZER

SELECTION

MATRIX 0

9 e

9 «

freezer

(SHUTTLE)

•

Factor

M IN
value

MAX

VALUE

PTS

C 0 N C
' 4

E P T
5

, . i*

Height

76*000

15t*p0

,00

5, 17

5*76

3,68

5,96

6 , 66

7,45

7,35

7*25

P (j & E S

38*000

363*.pO

*00

i2, n

10,00

5,q8

12,85

11.07

10.54

13,43

11*69

v atone

9 *2 DUO

9 * 2QqQ

.00

,00

• 00

*00

,00

' ,00

• 00

,00

ThER m al

I30-.RO

123R,g

,00

12,12

10*01

5*06

12*06

11*07

10,54

13*42

11*69

RFLI AB-Y

* V 7 6 17

. ,?94ft5

e 00

« 50

1,65

2 * 1 B

2.80

3, B5

2,13.

2*80

3*83

ha intenC

* 1 9 ? <? a

1,00000

,00

,&3^

1,74

1*83

2,51

3,57

1.03

2,5]

3*62

Safety .

.00 BOO

1 *O0"O -

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concept ... . . . ....

NO, CONCEPtNAHE

1 -* THEP^OELECTsIC-CAaiN AIR COOLING

. ... _ z - vapor compression-cabin air cooling* .

3 * STIRLING CYCLE-CABIN AIR COOLING

4 THtR^OELECTRIC-.'JATER COOLING {BO OEQ.J

5 - VAPOR COMPRESS 1 ON- A A TER COOLING ISO &EG.)

6 - STIRLING CYCLE-AATER COOLING (80 DEG*)

7 " THERHOELECTRI C-«ATER COOLING t45 DEf,»)

— * - a • VAPOR COMPRESS I ON- A ATE R COOLING (45 DEG.I

V - STIRLING CYCLC-V.ATER COOLING {45 DEg*1

zimvza

D2-11F572

2’1.4.5 Refrigeration Unit Design

Once the Stirling cycle concept was chosen as the type of system to be
used as the refrigeration unit, LTV Aerospace was assigned the responsi-
bility to size and package the unit for the freezer and to determine its
performance requirements. A detailed description of the theory and design
of the Stirling cycle unit can be found in Reference 12.

After sizing of the external freezer envelope and satisfying the storage
volume requirements, the remaining volume was allocated to thermal insulation
and the refrigeration unit. Calculations were made to determine the maximum
insulation thickness possible with enough volume remaining to accommodate
the R/U. An insulati-on thickness of approximately 2,0 inches was used and
a volume with dimensions of 9 n x 12 11 x 20“ was allocated to the R/U. Based
on'these conditions, the maximum design thermal load to the refrigeration
unit was 75 watts. This value includes heat leakage, effects introduced _
by compartment door openings and warm medical samples, and heat from the
cooling liquid pump. Characteristics of the conceptual Stirling cycle
refrigeration unit devised by LTV are listed in -Table 2.1-7.

2. 1.4.6 Mechanical Design and Structural Analysis

The function of the freezer structure is to provide support and restraint
to stored ..items and to the R/U. In addition, it also provides thermal
insulation of the stored volume from the ambient environment and acts as
a thermal conductor to the circulating coolant. Because the freezer is
to use the crew equipment storage module mounting system, the freezer
structural configuration was heavily influenced by the module design. A
cutaway illustration identifying the- basic mechanical design features of
the freezer concept is shown in Figure 1,5-1.

The freezer design consists of a number of individual elements of which
some serve functions other than structural. The structure is basically
two boxes, one inside the other and thermally insulated from one another.

D2-118572

TABLE 2.1-7

REFRIGERATION UNIT PERFORMANCE

o Refrigeration Cycle
o Cooling Rate

o Refrigerant
o Power Consumption

- Regulated 28 VDC
(Best estimate)

- 200 VAC 400 Hz

3 0 Regulated AC

TOTAL

o Coolanol 15 Heat Exchanger

- Pressure Drop At

Flowrate = 105. 3 Ib/hr
Flowrate = 210.6 Ib/hr

o Mass Properties

- Weight of Unit

- Center of Gravity

o Life

- Refrigeration Unit System

- Maintenance Interval
(Helium servicing, replace-
ment of motors, etc.)

Stirling

75 watts from Coolanol 15
(&70 watts excluding the pump)

Helium

176 watts (Range 115 to 200 watts)
30 watts (Fan)

206 watts

AP = 0.22 psi .

AP =0.44 psi

20 lbs

12.7 in. from Front Face,
Center of 5“ x 12" plane

8000 hours
2000 hours

2-55

D2-118572

2; 1.4.6 (Continued)

Fasteners which attach the freezer to the storage module mounts are located
on the outer box. The outer box is effectively suspended within the inner
box by foam-on-place polystyrene. Connection between the inner and outer
boxes is made at the front of the freezer by a one-piece framework on which
the door seals and hinges are mounted. Minor attachments between the two
boxes are made in back of the inner box. The refrigeration unit is located
on a pallet which attaches to the outer box.

An analysis was conducted to determine if the proposed design is adequate
to maintain the proper structural rigidity and integrity during the various
phases of the Shuttle flight envelope. The primary items investigated
were (1) mounting fastener loads, (2) thermal insulation deformation and
(3) inner box restraint. This analysis indicated the proposed freezer
structure was adequate for all imposed loads encountered during the Shuttle
mission.

2. 1.4. 7 Freezer Thermal Analysis and Evaluation.

Two thermal models were constructed using the SINDA (Systems Improved
Numerical Differencing Analyzer) thermal analyzer computer program to
select and verify the thermal design of the freezer. The first was a
simplified two-dimensional representation of a single slice through the
freezer. Its purpose was to examine the effect of spacing between the
coolant tubing. The second mod&l was a detailed three-dimensional nodal
network of the entire freezer, with capability for varying and analyzing
the effects of coolant tubing routing, medical sample insertion, refrig-
eration unit size and control scheme, structural thermophysical properties,
and other pertinent design details.

The two- dimensional model neglects corner and end effects and assumes a
semi-infinite plane with embedded coolant tubes spaced at regular intervals
Due to symmetry, it was necessary to model only one-half a section between

2-56

. D2-11S572

2,'1.4.7 (Continued)

two cooling tubes. -A **10°F coolant temperature was held constant in the
tubing, with 80°F ambient conditions. Steady state runs were made assuming
a distance between coolant tubes from 2 to 12 inches.

The effect of tubing spacing on the food temperatures is 'shown in Figure
2.1-ll(a) for a food thermal conductivity of 1.0 Btu/hr-ft-°F. An air/
packaging gap was included in the model between the food and wall. The
effective thermal conductivity of this gap was varied between 1.0 (equal
to that for the food) and 0.0 to determine the maximum and minimum effects
of this variable. The results in Figure 2. l-ll(b) show a maximum food
temperature variation between coolant tubes of 1.0°F with an eight (8) inch
tubing spacing. After considering other temperature gradients throughout
the freezer due to coolant warmup, edge effects, attach points, internal
conductive aluminum spacer walls, etc., this spacing was chosen as a general
guideline in initially routing the coolant tubing.

The three-dimensional model was developed to aid in selection of materials,
configuration, and mating of the storage compartment with the refrigeration
unit, and to provide verification of the final thermal design. The model
comprises 169 nodes and 656 conductors, and was constructed with generalized
inputs to accommodate continuing design changes. The model accounts for
all corner and edge effects, structural hard attach points, control schema,
and effects of door opening and medical sample insertion.

Transient results from the model are shown in Figures 2.1-12 and 2,1-13
for an 80°F ambient temperature. The input conditions for this case were
selected as representing worst-case ’design criteria. The maximum effect
of five door openings, beginning at 3 hours time, is seen in Figure 2.1-12.
■This effect includes the sensible and latent heat from an assumed 0.5 cubic
feet of air exchange with ambient surroundings for each door opening. The
temperature effect from this is minimal, and the total energy input is
negligible. At a time of 6 hours, a combined one-day's sample of urine

2-57

packaging

k t; V

packaging food :

Inner Wall

Figure. 2.1-11, Effecl

* Distance "x“ along inner wall - inch

(b) Temperature Profile Along Inner
Wall (d - 8 in.)

of Coolant Tubing Spacing
! Temperature

f t " I . I l i i i .

D2‘Si£572

Figure 2.1-12. Transient Freezer Thermal Response
Under "Worst-Case" Conditions

2-59

TEMPERATURE ^ / HEAT - WATTS

I 1 \ I f

D£-il£572 . ■ -

Figure 2.1-13. Transient Medical Sample Temperature and

Coolant Heat Removal under “Worst-Case'* Conditions

2-60

i #»*

D2-HS572

2.'1.4.7 (Continued)

and feces for seven men was inserted directly adjacent to cooling tubes
at the rear cold wall of the freezer. This sample v/as initially at 80°F
and contained a total of 2.15 pounds of water. The sample cool-down
profile is shown in Figure 2.1-13 (for a urine freezing temperature of
30°F) S and the effect on adjacent samples and the freezer coolant return
temperature is shown in Figure 2.1-12.

In Figures 2.1-14 and 2.1-15 are shown the results of a baseline case for
comparison with no medical sample insertion or door openings. Again,
ambient temperature v/as assumed 80°F. The refrigeration unit duty cycle
(fraction of the total time it is turned on) for this case was found
be 69 percent. Another run with identical conditions except for 70°F
ambient temperature resulted in a steady state duty cycle of 62 percent.

TEMPERATURE ~ °F TEMPERATURE -

D2-I1E572

Figure 2.1-14. Transient Freezer Thermal Response Y/ith

No Door Opening or Medical Sample Insertion

2-62

HEAT - WATTS

D2-IIF572

TIME »*> HOL'R'I

Figure 2.1-15, Freezer Transient Coolant Heat Removal

With No Door Openings or Medical Sample Insertion

i 1 . ( I *■ 1

D2-HS572

2.2 TASK 2.0, PREPARATION’ OF MATH MODELS

Future spacecraft analysis effort will require simulation of crew appliances
using the G-189A ETCLSS Computer Program, Reference 5. This program pro-
vides system level ECLSS performance simulation by performing mass and energy
balances throughout all the interactive components and flow loops comprising
a total ..system. Use of the G-189A program requires a subroutine for each
component in the system. These subroutines are all similar in that a standard
format of G-189A flow and thermodynamic data form the input for each. The
input data for a given component are taken from the output data from the up-
stream component. The subroutine then must modify these input data in a
manner which reflects the performance of the component it models, and present
the output data in the required G-189A format. The program allows the user
to control or modify the solution as it progresses by calling two subroutines,
GP0LY1 and GP0LY2, immediately prior to and following each component solution.
These routines may be used, for example, to alter fluid flow paths, turn
components on or off, reevaluate component model data based on the current
solution results, and compute and store parameters for later plotting.

The optimum. appliance concepts selected from the trade studies in Section
2.1 are shown in Tables 1.1-1 and 1.1-2 for Shuttle Orbiter and Modular Space
Station. Some of these concepts do not require a new G-189A subroutine
since (1) a routine is already available, (2) no thermal/mass exchange is
involved, or (3) operation of the component is so simple it requires only a
minor addition to the GPQLY routine logic. Appliances in this category are
as fol 1 ows :

o Reusable dishes, wet None needed

and dry wipes

o Vomitus collection None needed

o Partial body washing. Simple GPOLY logic only

wet wipes required

o Partial body drying, dry None needed {or a simple

wipes or electric dryer heater using G-1.S9A routine

ALTCGM)

2-64

D2-118572

2.2 (Continued)
o Wet shave

‘ o Windup razor
o Toothbrush

o Vacuum refuse collection
o Tape recorder, TV

GPOLY logic required for
water usage only

None needed (or a simple heater
using G-189A routine ALTCOM if
electric)

GPOLY logic required for water
usage only

GPOLY logic only required, or
G-189A routine ALTCOM for an
electric heater

For the remaining appliances, six new G-189A subroutines have been written,
some of which will model more than one type of appliance. These subroutines
have been designated as G-189A component subroutines number 66 through 71,
and are generally described as follows:

Subroutine Subroutine

Number Name

71 CHILLR

FT RAY

ROSKOS

SHOWER

Description

(simulates a thermally insulated locker cooled
either by an externally chilled fluid or a
self-contained refrigeration unit)

* Freezer .

* Refrigerator

* Food ‘wamnng /serving tray (Sfcylab-type)

* Reverse osmosis waste water treatment unit

* Spacecraft whole body shower

2.2 (Continued)

D2-HS572

Subroutine

Number

Subrouti ne
Name

WASDRY

WASTEC

Description

* Clothes washer

* Clothes dryer

* Combined clothes washer/dryer

* Dishwasher/ dryer

* Towel /cloth drying rack

* Dryjohn

* Uri nal

The subroutines have been written in conventional Fortran V language and
are operational on the NASA JSC SRU 1108 EXEC II computer system. They are
described in the "Crew Appliance Computer Program Manual 11 , Reference 2,
with detailed math model descriptions, solution methods, user's input
instructions, results of verification runs, and demonstration of their
operation in all-up Shuttle Orbiter and Modular Space Station ECtSS simu-
lation runs. A brief description of the component operation and mathematical
model used for the new appliance subroutines is given in Section 2.2.1.

Each subroutine was checked for accuracy and operational status within the
G-189A program by performing selected verification runs. These runs are
described in Section 2.2.2.

* ...

2.2.1 Computer Routine Development

In this section are included brief descriptions of the component operation
and math model used for each of the new appliance subroutines. Complete
subroutine descriptions are presented in detail in the "Crew Appliance
Computer Program Manual", Reference 2, Chapter 3. The basic approach was
to develop new subroutines only for the specific appliance components not
already included in- the G-1S9A component subroutine library. For example,
for the clothes washer/dryer, the WASDRY subroutine models the thermal /mass

2-65

D2-118572

i ;

2,2.1 (Continued)

exchange in the agitator or drum only, with the peripheral pumps, valves,
accumulator, etc., to be simulated by available G-189A component routines.

A major part of each appliance subroutine is the thermal model used to
simulate the heat transfer within the appliance and between the appliance
and its surroundings. An equivalent electrical resistor/capacitor nodal
network was used in each case for this purpose. These nodal models are
shown for the various appliances in the following sections using these
symbols:

““"tyVW\AAr—“

Node with thermal mass

Steady-state node

Boundary node

Thermal conduction or
convection conductor (linear)

Thermal radiation conductor (nonlinear)

One-directional fluid flow conductor

Other heat addition

Thermal capacitance

Thermal ground

Nodes having thermal mass are solved by equating the net heat input to the
change in heat storage. A thermal capacitance is specified for these nodes,
as defi ned by the rel ati on

C = me

where : C = nodal thermal capacitance

m ~ nodal mass
Cp - specific heat

2-67

D2-1IS572

2.2.1 { Continued)

Steady-state nodes are used to model gaseous fluid or other special nodes
having negligible thermal mass. These nodes are in thermal equilibrium
with their surroundings; that is, their temperature is computed such that
the heat in is equal to the heat out. Boundary node temperatures are not
computed in the subroutines. They must be input by the user and may be
held constant or varied during a run based on the progressing solution.

The nodes are interconnected by thermal conductors evaluated in the following
ways:

G =

solid conduction

h c A s

fluid convection

fluid flow

radi ati on

where G = thermal conductor

k - material thermal conductivity
A - "window" area between nodes
A g = surface area of node

& = length between nodal centers

m = fluid mass flow rate

|v = convection heat transfer coefficient
c

a = Stef an-Bol t'zmann radiation constant
’S- = radiation interchange factor

The first three conductors are referred to as linear and transfer heat
proportional to the first power temperature difference (T. - T^)* The
fourth conductor is radiation which transfers heat as a function of the
fourth power temperature difference (T. 4 - T- 4 ). Some conductors are

w * *

2-68

D2-1IS572

2.2.1 (Continued)

designated as "one-directional" elements, meaning that heat is transferred
through them in one direction only. This feature is typically used for
fluid flow simulation, in which the stored energy travels downstream only,
and also used for satisfying certain boundary conditions at a line of
symmetry within a model.

2. 2. 1.1 CHILLR Subroutine Description

The CHILLR subroutine, designated as G-189A No. 71, will simulate a refrig-
erator or freezer cooled either by an externally chilled coolant {e.g.,
from a radiator coolant circuit) or by a self-contained refrigeration unit.

The model is generalized and may be used to simulate the configurations
shown in Figure 2.2-1.

The thermal model in either case is shown in Figure 2,2-2. In addition to
the thermal network shown in the figure, the locker inner walls and con-
tents are thermally connected to the ambient surroundings using the standard
G-189A subroutine QSURR. This routine models the heat exchange from an
arbitrary structure to ambient via insulation, thermal shorts, and conduction/
convection/radiation paths. The output from the QSURR subroutine defines
the heat loss from the internal structure to ambient, which is designated as

q surr in Figure 2 ' 2 “ 2 *

The CHILLR subroutine has been used to simulate the Shuttle food and medical
sample freezer kit described in Reference 3, Excellent correlation between
the subroutine results and independent detailed freezer thermal analysis has
been obtained. The model data used for that freezer design are included
directly in the subroutine as default input data.

2-69

I i

D2-I18572

Refri gerant
in

Q Fan (optional)

(a) Cooled by externally
chilled liquid

.Cooling.

Coils

m . '% /. (optional)

Chiller

#> n .

Refrigeration
Unit- t

_Coolant

(b) Self-contained refrigeration
unit with wrapped cooling coils

Refrigeration
Unit

Chiller
Cool ant
in

— : — v/j

Refrigeration
Unit

Chiller
Coolant
~ in

unit with cooling coil interface unit v/ith cold plate interface

Fig' -e 2.2-1. CHILLR Component and Flow Schematic

2-70

i i . « l 1 t

D2-Ufc'572 ' •

(a) Thermal model of refrigerator/freezer
locker including cooling coils

Cooling .
coils

Refrigeration
unit

i n

Cooling coils/
evaporator

S out

■'tow — 3-

(b) Thermal model of refrigerator/
freezer chiller side, including
cooling coils -assuming
externally chilled coolant fluid

Figure 2/2-2. Thermal Model of Refrigerator/Freezer
Locker (a) and Chiller (b) and (c)

2-71

D2-1I8572

2. 2. 1.2 FTRAY Subroutine Description

The FTRAY subroutine; designated as G-189A No. 66 , simulates the performance
of Skylab-type food warming/serving tray. A typical food tray, shown in
Figure 2,2-3, had eight recessed food cavities, of which three had embedded
thermostatically controlled electrical resistance heaters to warm the food.
The thermal model used for a single
food warming cavity is shown in
Figure 2.2-4. The cavity is assumed
cylindrical and is subdivided into
five food nodes of equal volume. In
addition to the thermal network shown
in Figure 2.2-4, the food is thermally
connected to the ambient surroundings
using the G-189A subroutine QSURR.

The subroutine has been correlated

with actual Skylab test data and Figure 2.2-3. Typical Skylab-type

excellent agreement obtained. Warming/Serving

Tray

Any number of heat.ed food cavities may be simulated by a single G-189A
component using FTRAY. The routine determines the performance of a
single food cavity and assumes all others are identical. If some food
trays have different input data or time schedules, they must be simulated
by separate .G-489A components.

2.2.1 .3 RQSMOS Subroutine Description

The R0SM03 subroutine, designated as G-189A No. 69, simulates a reverse
osmosis process used for removing impurities from waste water. Fluid is
forced by static pressures across a membrane in a direction opposite to
which it would normally flow due to osmotic pressure alone. Most of the

impurities are filtered out by the membrane, thus leaving a purified water

(„y . ..... . , , ■ , '. ■ , ■ ■ . . . ■ : : ' '. :

D2-118572

Food # cavity

Figure 2.2-4. Thermal Model of a Single
Food Warming Cavity

2-73

D2-11E572

2 .2.1. 3 (Continued)

’ *

flow through the unit.- This technique is in use commercially in many water
and waste treatment applications and is being developed to recycle space-
craft waste water. The subroutine will simulate the performance of an
arbitrary type of reverse osmosis unit, shown in Figure 2.2-5, if test or
design performance data for that unit are available. Only a single-stage
unit may be simulated by a single component, but multistage operation may
be achieved by connecting more than one unit together.

2-74

D2-lf£572

2. 2. 1.3 (Continued)

Since a particular spacecraft reverse osmosis unit design has not been
determined, the subroutine was written in general terms to handle any
unit for which some design or test data are available. The input design
data are adjusted for the off-design conditions present during a run.

The thermal balance of the reverse osmosis unit with ambient surroundings
is handled using the standard G-189A subroutine QSURR.

The flow balance across a reverse osmosis module may be analyzed from two
viewpoints of interest. First, one can consider the overall net effect of
all the different types of solute impurities, lumped together and treated
as a single homogeneous impurity. This approach is used in determining
overall water balances and initial sizing and design of water recovery com-
ponents. Secondly, one can consider the effect of the reverse osmosis module
on each different type of impurity present in the water with its own individ-
ual rejection factor. This subroutine uses the former “overall" approach
for handling the total flow balance, and will also apply the second approach
as an option for handling any number of individual impurities desired.

2. 2. 1.4 SHOWER Subroutine Description

The SHOWER subroutine, designated as G-189A Mo. 67, models the thermal and
evaporative mass exchange in a shower stall, as shown in Figure 2.2-6, The
G-189A subroutine QSURR is used to model the thermal exchange between the
shower stall frame and ambient environment. Evaporation is modeled by mass
transfer equations as a function of air inlet flow rate, humidity and
properties. The effect of the shower occupant is included by standard
metabolic equations based on input metabolic rate and the respiratory quotient.
The thermal nodal network assumed for the shower component is shown in Figure
2.2-7 for the occupied and unoccupied cases. The shower is assumed to be
occupied if and only if there is flow inlet to the primary (air) side. When
the water is turned on, the total (primary and secondary) water inlet and outlet

2-75

D2-1I8572

2, 2. 1.4 (Continued)

flowrates are equal. When the water is turned off with air flow only, the
outlet water vapor flow is equal to the inlet flow plus the amount of water
evaporated. *

Air Water

inlet inlet

(primary) (secondary)

(primary)

Figure 2.2-6. Shower Model Flow
Schematic

D2-118572

cond

(a) Unoccupied

(b) Occupied

Figure 2.2-7. Thermal Model of Shower Stall Component

2.2.1 .5 WA5DRY Subroutine Description

The WASDRY subroutine, designated as G-189A No. 70, will simulate operation
of the following appliances:

o Clothes washer
o Clothes dryer

o Clothes was her/d ryer combination
o Dishwasher
o Dish dryer

2-77

D2-118572

2.Z.1.5 (Continued)

♦

o Dishwas her/dryer combination
o Towel/cloth drying rack

A flow schematic of the WASDRY component is shown in Figure 2.2-8, Seven
operational usage phases may be simulated:

Phase 0 - Unit off
Phase 1 - Wash water fill
Phase 2 - Wash (circulate)

Phase 3 - Spin dry - wash water out
Phase 4 - Rinse water fill
Phase 5 - Rinse (circulate)

Phase 6 - Spin dry - rinse water out
Phase 7 - Dry

The routine will control the switching between phases based on input cycle
schedules if requested by the user. Thermal exchange between the tub and
frame and the ambient environment is modeled using the standard G-189A
library routine QSURR. During the drying phase, the evaporation process
is modeled in detail as a function of air inlet flow rate, humidity and
properties, velocity within the tub, and water retention in the load. The
thermal nodal network used to simulate the WASDRY component is shown in
Figure 2,2-9. The subroutine models the thermal /mass exchange in the
agitator or tub only, with the peripheral pumps, valves, accumulator, etc. to
be simulated by standard G-189A component routines.

2.2.1 .6 WASTEC Subroutine Description

The WASTEC subroutine, designated as G-189A No. 68, will simulate a urine/
fecal waste coll actor applicable to space use, such as a urinal or dryjohn.

A flow schematic of the WASTEC component is shown in Figure 2.2-10. Three

2-78

D2-1IE572

(a) Washer/dryer .

(b) Towel/cloth rack dryer

Figure 2.2-8. WASDRY Component Flow Schematic

Water

inlet

Air

inlet

Air.

inlet

m,C„

"s~p T

T VWVir- »tp a 0Ut

•a*

■ in

Towels/cloths

•"HI — i

*evap

6. . S
tf s

,j Hh

•“surr
Rack fixture

(a) Washer/dryer

(b) Towel /cloth rack dryer

Figure 2.2-9. Thermal Modal for WASBRY Component

D2-1I8572

2.2.1. 6 (Continued)

operational usage phases may be simulated:

Phase 0 - Unit off

Phase 1 - Urine collection

Phase 2 - Fecal collection

Phase 3 - Combined urine/fecal collection

Air/

Air flush water

outlet . . outlet-

Figure 2.2-10. WASTEC Component Flow Schematic

Commode contents may be under vacuum, if requested, during phases 0 and 1.
Each time vacuum is initiated following operation of a fecal collection
phase (2 and 3), a pumpdown or blowdown is automatically performed. During
vacuum drying, the latent heat of evaporation or sublimation is computed
from standard vacuum drying equations.

Thermal exchange between the collector and ambient environment is modeled
using the standard G-189A library routine QSURR, The thermal nodal network
used to simulate the component is shown in Figure 2.2-11. The subroutine

P2-ii£572

2. £.1.6 (Continued)

models the thermal/mass exchange in the collector and urinal only, with
the peripheral pumps, valves, etc. to be simulated by standard G-189A
component routines.

Collector Urinal

inlet inlet

Figure 2.2-11, Thermal Model for WASTEC Component

^tsr’

2-81

P2* 11857 2

2.2.2 Validation of Routines

2. 2. 2.1 Individual Appliance Subroutine Checkout

The new c rev/ appliance subroutines have been run in the G-189A program to
verify their accuracy and operational status. First „ each component modeled
was run separately (i.e. , not connected in an all-up system model) with
dummy ambient and inlet flow conditions. These conditions were held con-
stant during a run and a steady state and transient solution obtained. The
results of these checkout runs are described in the Crew Appliance Computer
Program Manual, Chapter 4. Calculations are presented to verify conserva-
tion of mass and energy within the components, and the solutions compared
with test data where available. The results were found to be reasonable
and accurate, and excellent agreement with test data was achieved where
available. Many of these appliances have not yet been built for spacecraft
application, and the available test data required for correlation of the
models v/as limited. For such cases, further testing and model correlation
are recommended when the actual hardware is designed and built.

2.2. 2.2 Shuttle Orbiter Appliances Simulation

To demonstrate that the appliance subroutines are operational in an all-up
G-189A system simulation, they were run in a Space Shuttle Orbiter and
Modular Space Station G-T89A ECLSS model. The appliances included in the
models were taken from the concept trade studies and represent the optimum
set of appliances for each vehicle. The only Shuttle appliances selected
which required the new G-189A appliance subroutines were a space radiator
refrigerator, food heating/serving trays, and a dryjohn. Since a refriger-
ator is currently not included in the Shuttle design and since the Shuttle
cabin coolant loop would be only marginally effective for the space radiator
concept, the refrigerator was not included in the Shuttle model . (Both
refrigerators and freezers were included in the Space Station model in
Section 2. 2. 2. 3).

2-82

D2-11S572

2. 2. 2. 2 (Continued)

An available steady-state 6-1 89A model of the Shuttle Orbiter ECLSS developed
by Me' Donnell Douglas Corporation (MDAC) was used for the basic Shuttle
system model. This model obtains a single steady-state solution for up to
23 different mission phases. For the purpose of verifying the appliance
subroutines, this model was run for mission phases 12, 13, 14, and 15 which
represent four different days of normal orbital operations. Two cases
were run. First, an unmodified case was run with all program inputs exactly
as supplied by MDAC. No appliances or modifications were included

A dryjohn and food heating trays were then added to the basic Shuttle model,
and the same case was rerun. A flow schematic of the G-18SA components
added to the basic Shuttle case is shown in Figure 2.2-12. The dryjohn air

inlet and outlet were connected directly to the secondary side of component
2, which was the Orbiter cabin in the basic model. The food heating trays
were not connected directly in any fluid flow loop; thus, no components
are shown attached in Figure 2.2-12.

To exercise ‘various appliance subroutine options, different conditions were
assumed during each of the four mission phases, as shov/n in Table 2.2-1.
Complete results from the Shuttle appliance system runs are presented and
discussed in the Crew Appliance Computer Program Manual, Chapter 5. The
results demonstrate that the new appliance subroutines are valid and work
properly in an all-up G-189A syst.em model.

2. 2. 2.3 Space Station Appliances Simulation

To demonstrate that the new appliance subroutines are operational in an all-
up G-189A system simulation, they were run in a Space Shuttle Orbiter and
Modular Space Station G-189A ECLSS model. Since no operational model of the
complete Space Station ECLSS was available, a simplified model of the
pertinent subsystems was developed in which to check the appliance subroutines.

2-83

Vacuum

P2-HE572

C*bln *Ir in
frwi l? s

10 « s

Figure 2.2-12. Flow Schematic of G- 189ft Appliance Components
Added to Basic Shuttle Orb iter Model

DM8572

TABLE 2.2-1

APPLIANCE COMPONENT OPTIONS ASSUMED
IN SHUTTLE ORBITER SIMULATION

D R Y 0 0 H N

FOOD TRAYS

J MISSION

USAGE

CABIN AIR FL0W,CFM

TOTAL NUMBER

PHASE

DESCRIPTION

URINAL

COLLECTOR

BEING HEATED

0 .

Not in use

0 j

Vacuum dry

i 13 • .

Urine collection
Vacuum dry

2 j

' !

2 -

Fecal collection

Combined urine/
fecal collection

15 .

! -

. 1

D2-118572

2.2.2. 3 (Continued)

#■

The Modular Space Station concept (Reference 11) involves eight separate
compartments for crew habitability, work, experiments, etc. Only two of
these compartments were included in the model. The first includes most
of the personal hygiene equipment, and the other the crew eating and
sleeping quarters. The G-189A flow schematic for these cabins and associated
appliances is shown in Figure 2.2-13. The water loop used to supply these
appliances is shown in Figure 2.2-14. Flow schematics for the other appli-
ances not included in these two flow loops are shown in Figure 2.2-15. The
appliances were run in a 10-hour transient simulation according to a typical
daily schedule shown in Figure 2.2-16. The following appliances were
included in the. Space Station model:

- Refrigerators

- Freezers

- Food trays

- Reverse osmosis unit

' - Shower ’ .

- Clothes washer/ dryer

- Dishwasher/dryer

- Dryjohn

- Wet wipe wetting unit

The G-189A flow networks used to .describe the shower, clothes washer, dish-
washer and dryjohn are shown in Figures 2.2-17 through 2.2-20. For the other
appliances, only the single new G-189A component described in Section 2.2.1
was required. The operation of the ECLSS system and each individual appliance
is discussed in detail in the Crew Appliance Computer Program Manual,

Chapter 6. Complete model input and output data are presented, with plots
showing transient cabin temperatures, humidity, CO 2 levels, and the thermo-
dynamic performance of each of the appliances. The results demonstrate that
the new crew appliance subroutines are accurate and operational within the
G-189A computer program environment.

■ 78

SPLIT(iq)

SPLIT (10)

SPHT(IO)

■ 70

CABIH(l)
Hygiene Area

Wipe Hotting
Unit •

ALT COM (‘13}

r~r |

! •' I15p j

’SHOWER

CLOTHES

CMA’l(S)

GASMIX(G)

GASMIX(fi)

GASMIX(G)

ALTC0:i(49)

SPLIT(IO)

. CMAHC3)

split (ib);

SPLIT (10)

■ Flow path not included .

in model

XX G-189A Component Number
(XX) G-189A Subroutine Number

CABIH(l)

Galley

62 .
Freezers
CHILLR{71}

DISH

HASHER

L' J

64 !

Cabin, H/X, Fan
Other Equip.
ALTCOMWl

? P

GASMIX(5)

GASMIX(6) •

I - r

I , l

** *

Figure 2.2-13. G-189A Flow Schematic of Space Station Cabin Gas Loop

D2-118572

Liquid

*“'* Flow; path not included

in model

XX G-189A Component Number
(XX) G-189A Subroutine Number

Figure 2.2-15. Other G-189A Components Used
in Space Station Model

t C'J

Men Jn.G alley u

J:len 1 r._Hyciene Area
. j tterriri , Other Are_as _

Cl othes Wash/ R i nsej.
Clothes Dry

Food Warr.i ng Trays (6)
.Shower

Dishes Wash/Rinse

ishes Dry

Rsfri geratbr (x- door open
Freezer. (x- door open) ,

.Qryjohn. -..urinal

Dryjohr - commode

Wet Vhpe Wetting Unit_ ^

3 3 3 3

3 ■

— »

1 I

• S

■■ | in ^

I — It-

1 1

—

___ J — ; — - — 3 _ ‘

l (~i ( — H ' ;

13 1\

V V* O

* ® ** #

— - • -Typical iKater-on
... Shower.. (Water .of:
Schedule

}

sac

ttsst:

38K.

3 10 minutes

’ Water in
from #86,

D2-11857 2

Air out
to #S0 p

to m p

. Figure 2.2-17. G-189A Flow Schematic of Space

Station Shower Model

Warm

Coolant

D2-1I8572

- Air in

D2-IIC572

Air In

D2-U8572

Cabin air In
from f72„

Air out
to #75 s

Water out
to 092 p

Figure 2.2-20. G-189A Flow Schematic of Space Station Dryjohn Model

D2-I18572

♦

2:3 TASK 3.0, GENERATION OF DEVELOPMENT PLANS

Development plans were generated for the selected optimized integrated
crew appliance systems for the Space Orbiter and the Space Station. These
development plans provide a cost-effective approach for appliance subsystems
development. The approach is based on resolution of appliance weaknesses
and deficiencies identified during the study.

The plans are structured to define the technical approach recommended for
resolving the appliance subsystem weaknesses through further analysis, design
and testing. A proposed schedule for phasing of the development effort was
presented for selected appliance concepts. A summary of the plans presented
are contained in Table 2.3-1.

2.3.1 Shuttle "Kit" Freezer Development
Discussion

The desirability for a varied food diet on long duration missions, which cannot
be achieved with rehydrated foods, is recognized. To provide facilities for
the frozen -storage of whole food items, as well as medical samples, on board
the Shuttle Orbiter a conceptual study has been conducted. Results from this
study demonstrated the feasibility of a self-contained unit, requiring only an
electrical power interface, which can be developed to satisfy the required
storage volume and thermal environment and can be effectively mounted in the
Orbiter crew compartment.

Technical Objective

The objective of this program is to develop a self contained freezer “kit" to
provide storage for food and medical samples.

Approach

Primary elements of the "kit" freezer include the storage box and the re-
frigeration system. The storage box is a conventional freezer design of
inner and outer box structure with polystyrene foam thermal insulation between.

. 2-95

D2-11E572

Table 2.3-1 APPLIANCE DEVELOPMENT PLANS SUMMARY

HABITABILITY

SUBSYSTEM

HABITABILITY

FUNCTION

APPLIANCE
FUNCTION ‘

DEVELOPMENT PLAN STATUS

FOOD

STORAGE

REFRIGERATED

FROZEN

PROPOSED DEVELOPMENT PLAN
(PARAGRAPH 2.3.1 J

FOOD

HW1AGEHENT

FOOD

PREPARATION

HARMING .

STATE OF THE ART

GALLEY

CLEANUP

DISH CLEANUP

PROPOSED DEVELOPMENT PLAN
(PARAGRAPH 2.3.2)

■

HASTE

COLLECTION

FECAL

COLLECTION

URINE

COLLECTION

GENERAL ELECTRIC DEVELOPING SYSTEM
FOR SHUTTLE

V DM ITUS
COLLECTION

STATE OF THE ART !

BODY

CLEANSING

SHOWER

PARTIAL BODY
HASHING

PROPOSED DEVELOPMENT PLAN
(PARAGRAPH 2.3.3)
CURRENTLY ON-GOING STUDY

PERSONAL

HYGIENE

PARTIAL BODY
DRYING

STATE OF THE ART ASSUMING A CLOTHES
WASHER

SHAVING

STATE OF THE ART

HAIRCUTTIHG

STATE OF THE ART

PERSONAL

GROOMING

KAIL CARE

5TATE OF THE ART

DENTAL CARE

STATE OF THE ART

EQUIPMENT
CLEANUP _ .

SURFACE

WIPING

CURRENTLY ON-GOING ‘STUDY

MANUAL

COLLECTION

STATE OF THE AM

HOUSEKEEPING

REFUSE

MANAGEMENT

VACUUM

COLLECTION

REFUSE ...
PROCESSING

STATE OF THE AM
STATE OF THE ART

REFUSE

DISPOSAL

STATE GF THE ART

ran

PRO' OSED DEVELOPMENT PLAN
(PARAGRAPH 2.3.2)

MUSIC

STATE OF THE ART

OFF-DUTY

ACTIVITIES

ENTERTAINMENT

LIBRARY

TELEVISION

GAMES

STATE OF THE ART
STATE OF THE ART
STATE OF THE ART

iB&EBBi

EUTCisors

■ "TATE OF THE ART

^RtBSIAL page is
Of POOH QUALITY

2-96

D2-11E572

2/3.1 Continued

The refrigeration system consists of a circulating coolant used to transfer heat
from the storage box to the refrigeration unit. The refrigeration unit employ
a Stirling cycle principle cooler to pump heat from the coolant to the
cabin atmosphere.

A prep>"ototype of the freezer storage box (all freezer components except
refrigeration unit (R/U)) will be fabricated and tested to define the freezer
thermal characteristics. This box would be fabricated to the conceptual
design with necessary refinements. Coolant temperature and flow-rates will
be easily simulated without the necessity of a refrigeration unit. Thermal
environment simulating the Orbiter crew compartment can be economically ac-
complished at s-ea level pressure. Using this test article, the validity of
the thermal model calculations will be determined and the necessary refine-
ments to the model made to provide a more accurate characterization of the
freezer. These tests will determine if the volume allocated to the R/U is
adequate or not. In the event it is not, the amount of insulation must be
reduced (therefore an increase in thermal load to the R/U) and the R/U re-
sized. Trades of amount of thermal insulation versus R/U volume requirements
can be conducted with greater confidence using the results of the preproto-
type test and a refined thermal model.

The refrigeration unit preprototypa would be an accurate representation of
the conceptual design in all respects except the drive mechanism. The
drive mechanism proposed has been utilized on other Stirling refrigeration
systems, and it would not be necessary to demonstrate its feasibility at
this point in the development. A bench test setup using an external drive
system would be employed to investigate the major operating parameters of
the Stirling system or head of the unit. Cycle efficiency, electrical
power requirements, cyclic frequency effects, and cooling requirements will
be established. These tests will also aid in determining the R/U volume
and weight requirements. However, the R/U mechanism (except the drive) will
be fabricated to the conceptual design specification for possible use in
prototype testing in the event the preprototype tests demonstrate its
performance is satisfactory. The head will be designed to adapt to the
more sophisticated drive mechanism used on the prototype.

D2-11E572

2.3.1 Continued

A prototype freezer will be tested to investigate the performance of the
storage box and refrigeration unit combination. The prototype wi 1 1 utilize
the preprototype storage box and refrigeration unit unless the preprototype
testing and analysis indicates that these units must be radically resized.
This is not anticipated with the storage box since some allowance for an
oversized R/U can be accommodated in the box insulation in the area above
the pallet.

Testing of the prototype freezer will be conducted to assess the performance
of the complete refrigeration system. Items to be investigated are:

o R/U component life

. o R/U cooling system efficiency

o Nominal and off-nominal operation
o Temperature control system
o Storage box temperature profiles
o Optimum cooling liquid flowrate

o Ice build-up inside storage volume and on stored items

Since a considerable amount of zero "g" operating experience has been
accumulated on the Stirling principled coolers, zero “g" testing will not
be necessary. A flight article can be fabricated from the information
gained from prototype testing. The proposed development :chedule is shown
in Figure 2.3-1.

2.3.2 Washer/Dryer Combination (Dishes and Clothes) Development
Discussion

Mechanical washer/dryer for dishes and clothes has potential application for
long duration space missions (greater than 180 days). This appliance would
eliminate the necessity for the launching with many disposable items such as
crewmen's clothes, linens, cleaning and drying cloths, and dishes and eating
utensils and provide a savings in weight and volume. Using a water spray
agitation concept permits washing of both rigid and non-rigid items in the
same end r sure; eliminating the need for two individual appliances and
consequently providing a reduction in development effort.

2-98

YEARS FROM GO-AHEAD

ACTIVITY

STORAGE BOX
PREPROTOTYPE
o DESIGN &
FABRICATION
0 TEST &
ANALYSIS

REFRIGERATION UNIT
PROTOTYPE
q DESIGN STUDY
0 DESIGN &
FABRICATION
o TEST &

ANALYSTS

REFRIGERATION UNIT
DRIVE MECHANISM
o DESIGN &
FABRICATION
o TEST &

ANALYSIS

FREEZER PROTOTYPE
o DESIGN &
FABRICATION
o TEST &

ANALYSIS

Figure 2.3-1. Freezer Development Schedule

D2-HS572

2.3.2 Continued
Technical Objective '

The objective of this effort is to develop an appliance for long duration
space station application which will function as a washer and dryer for
items normally identified as disposable.

Approach

A dual function washer/dryer combination to operate in a space station
environment is feasible using water spray agitation as the cleaning mode and
electrically heated circulating air as the method of drying. A rack to
restrain the washer load when used as a dish washer is removed when the
washer operates as a clothes washer. Pulsating, high velocity water jets
are directed onto the load from all sides to provide effective agitation
and to prevent clothes from trapping against the washer sides. Circulating
air transports the water from the washer to the water separator. Verifi-
cation of this washer concept by ground testing would be difficult, since
accurate simulation of the zero "g" suspension of clothing is impractical.
Feasibility of water to control the position of the clothes load in the
washer should be investigated in zero "g" aircraft tests. However, demon-
stration of cleaning and rinsing effectiveness and the water transporting
system must be conducted in orbital flights of sufficient duration.

No technological problems are foreseen in the operation of this concept in
the drying mode. Air jets, designed to center the clothes in the dryer,
will induce a tumbling action to the clothes as well as provide a drying
medium.

Ground test data for commercial vendors' models and space oriented prototypes
will provide some data which can be related to the flight . test item. Effective-
ness of water cleaning of dishes as well as convective air drying will be
investigated from these data. Electrical power requirements for heating
of wash water and drying air, plus optimum cycle times will be established.

The proposed development schedule is shown in Figure 2.3-2,

’GO

YEARS FROM GO-AHEAD

ACTIVITY

DATA COLLECTION
& REVIEW

CONCEPT

DEVELOPMENT

PROTOTYPE
WASHER/ DRYER
0 DESIGN &

fabrication

0 GROUND TEST
& ANALYSIS
0 LOW “G n FLIGHT
TESTING &
ANALYSIS

FLIGHT UNIT
o DESIGN &
FABRICATION
o ORBITAL TEST &
DATA ANALYSIS

ti+m J

Figure 2.3-2. Washer/Dryer Development Schedule

D2-112572

2.3.3 Shower Development
Discussion

Whole body cleaning becomes a mandatory requirement as mission durations,
extend. A whole body shower has been found to be the most reasonable ap-
proach for this bodily function. This appliance, using proper design, can
greatly reduce the crew member washing time which has been for the most
part accomplished by partial body washing techniques. The trade studies
have indicated a collapsible shower, similar to the Skylab design, is
the optimum approach for this appliance. The technical approach recommended
is based principally on the literature surveys conducted during the study
and experience gained during shower test support activities conducted at
NASA- JSC.

Technical Objective

The objective of this effort is to develop an appliance for long duration space
station application which will function as a whole body shower for crewmembers.

Approach

Several designs of whole body showers have been advanced, however all have
a common problem of a good water pickup technique. The water pickup technique
must be incorporated into the shower design in conjunction with the selection
and design of the enclosure. The biggest crew complaint of the Skylab shower'
was the long laborious job of water pickup. A water pickup system must there-
fore be designed which will speed the process of loose water pickup. A
collapsible semi-rigid enclosure should be considered to exploit its obvious
advantages of lower weight and volume. Water/air separation must be improved
to handle a greater latitude of cleaning soaps. Present designs do not allow
for separation of high sudsing soaps which are normally more comfortable to
the user. Concurrent with this study, a low sudsing soap should be investi-
gated which does not leave an "oily feeling" like Miranol after usage. Water/
air separator techniques should consider a dynamic technique for zero "g" usage
in addition to consideration of baffles or screens for anti-foaming action.

D2-118572

2.- 3. 3 Continued

The shower system should be ground tested for acceptance testing and
personnel evaluation. Aircraft low gravity tests should be conducted to
evaluate the water pickup and water separation systems. Finally, a flight
configuration should be tested, for instance, in the Shuttle payload module
to evaluate the system under long term zero gravity conditions. The proposed
development schedule is shown in Figure 2.3-3.

2-104

YEARS FROM 60- AHEAD

ACTIVITY

DATA COLLECTION &
REVIEW

CONCEPT DEVELOP-
MENT

0 ENCLOSURE
ANALYSIS ,

DESIGN & TEST
o WATER PICKUP/
SEPARATION
ANALYSIS,

DESIGN & TEST

SJ^ DEVELOPMENT

PROTOTYPE SHOWER
o DESIGN &
FABRICATION
o GROUND TEST &
ANALYSIS

o LOW "G" FLIGHT
TESTING &
ANALYSIS

FLIGHT UNIT
o DESIGN &
FABRICATION
o ORBITAL TEST &
DATA ANALYSIS

Figure 2.3-3. Shower Development Schedule

D2-II8572

3:0 ’ RESULTS, CONCLUSIONS, AND RECOMMENDATIONS

The Shuttle Orbiter appliance system defined by this study is within the
currently allocated thermodynamic, electrical power, weight, and volume
vehicle requirements. Appliance concepts selected by the trade studies ,
and optimization techniques applied during the study showed that disposable
appliance concepts were the best compromise for the Shuttle Orbiter appliance
system.

The appliance system described for the Space Station was one which offers
the optimum in crew convenience with minimum impact on thermodynamic,
electrical power, weight, and volume vehicle requirements. Establishment
of a firm set of Space Station thermodynamic and electrical power require-
ments are needed for future appliance studies.

Crew performance/ convenience requirements were found to drive the selection
of the appliance concepts for the optimum system. Therefore, the selected
appliance concepts based on the weighted trade study were, in many cases,
not the concepts chosen as a result of the subsystem and system optimization.
The weighted trade study did not account for crew preference/ convenience
due to the difficulty of developing an objective rating system without
satisfactory reference data. Future studies should provide a survey of
astronauts in order to derive statistical crew approval ratings of the
various appliance concepts which could be factored into the computerized
weighting trade program.

The computerized weighting trade program developed during this study proved
to be an excellent method to objectively select the best appliance concepts
in terms of weight, power, volume, thermodynamics, reliability, maintain-
ability, safety, development cost, and resupply. Advantages of the trade
•program are rapid rerating of appliance concepts caused by trade parameter
changes, a convenient, flexible, and quick method for comparing numerous
appliance concepts, and easy manipulation of trade parameter weighting
distribution. Future programs should consider this computerized trade
program as a necessary tool for an objective selection of systems with
numerous competitive concepts.

D2-H257?

3.0 Continued

A Crew Appliance Bibliography of 682 references was compiled in a computerized
format using a generalized data handling program, COMPOSIT‘77, available on
the Commander- 1 1 System of Corn-Share timesharing computer located at Ann Arbor,
Michigan. This bibliography can be easily accessed remotely and with periodic
updating will provide a comprehensive listing of the current appliance re-
ference data. These data can be retrieved by reference number, title,
author(s), date, publishing organization, contract number, NASA-JSC library
number, and/or subject matter.

Selected appliance concepts were modeled within the G-189A framework and
were demonstrated to be compatible with the G-189A program. These sub-
routines provide a tool for future appliance analysis. The models are
flexible, with generalized input, such that many different appliance con-
cepts or designs can be handled by a single subroutine. Since many of these
appliance concepts have not yet been designed or built for spacecraft ap-
plications, additional appliance testing is required before correlation of
the subroutines to actual test data can be made. -

Appliance trade studies for a space station having a resupply period of
180 days have shown that a clothes was her/dryer and dishwasher are not the
optimum conceptual choice. These appliances were specified for this study
to provide the maximum appliance utility and minimum consumables requirements.
Further study is warranted to develop data necessary to perform a detailed
trade study of the interrelationship of crew time with thermodynamic and
electrical power requirements.

Test support activities have successfully demonstrated the long term operation
of the Oxygen Generation Subsystem. This subsystem electrolyzes water into
hydrogen and oxygen. Oxygen will be used for cabin leakage and metabolic
leakage makeup and hydrogen will be provided to the COg Collection Subsystem,
thus allowing for CGg removal from cabin air. Shower testing (in excess of
60 showers) has attained high marks for personal acceptance with water usage
per shower averaging .50 to .75 gallons. The method of water pickup after
showering should be improved.

3-2

D2-I18572

3.0 Continued

The Shuttle "kit" Freezer Study has demonstrated the conceptual feasibility
of a portable “kit 11 freezer which will satisfy the stated food and medical
sample storage requirements for Shuttle operation. The conceptual freezer
can be passed through the Orbiter side hatch fully assembled and can be
mounted on existing storage module supports, located in the Orbiter crew
compartment, using standardized fasteners and tools. Total design launch
weight of the freezer and contents of 285 pounds is within the maximum weight
restraint capability of the storage module supports. Conventional construc-
tion techniques are employed in the conceptual freezer which will require
short lead times and economy in fabrication.

The self-contained refrigeration unit requiring 206 watts peak electrical
power will provide a safe and efficient cooling system with a coefficient
of performance (C.O.P.) of 0.355. The steady state duty cycle is approxi-
mately 69% with an 80°F ambient cabin temperature.

Thermal analyses of the freezer have shown the cooling capacity of the
refrigeration unit is sufficient to maintain the storage box structure and
contents at 0.0°F or below after medical sample insertions and door openings.

A warm medical sample can be cooled from 80°F to 30°F in approximately 3 hours.
The steady state heat leakage rate of the storage box is 46.4 watts with ari
ambient temperature of 80°F and an average storage temperature of -10°F,

Limitation of volume allocated to the freezer results in a thermal insulation
thickness which is .less than optimum. This also impacts the sizing of the
refrigeration unit since it must provide rejection of the additional thermal
load at the expense of weight and electrical penalties. Because of the
criticality of the freezer insulation properties, it is recommended that the
thermal characteristics of the freezer box be carefully validated early in
the freezer development program. If tests reveal the thermal load to the
refrigeration system is greater than predicted, then two options are available:

3-3

D2-U8572

3.0 Continued

1. Increase the insulation thickness at the expense of storage
capacity.

2. Increase the cooling capacity of the refrigeration unit with
the inherent penalty of weight and electrical power increases.

Design, fabrication, and testing of the freezer can be accomplished with a
relatively small investment and will provide valuable information to firm
up the freezer configuration. These tests will make a definite establish-
ment of the volume which can be allocated to the refrigeration unit, and the
R/U volume constraints must be defined with reasonable certainty before a
cost-effective R/U development program can be initiated.

An integrated appliance/ECLSS E-189A computer model should be developed to
(1) determine optimum hook-up between the appliance and spacecraft systems,
and (2) establish system timeline characteristics. This model would provide
the data necessary for the most efficient utilization of crew appliances.

3-4

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